Electronic card having an electronic interface

ABSTRACT

This disclosure is directed to an electronic identification card or electronic card having various features. The electronic card may include an integrated circuit and a contact plate for electrically interfacing with the integrated circuit. The contact plate may include an array of terminal electrodes that are offset with respect to the edges of the contact plate. The electronic card may be coated with a coating layer that extends at least partially over a ferromagnetic element or film. The electronic card may also include a metal substrate having exposed chamfer portions that may provide a visual contrast to the coating layer and also improve the handling and use of the electronic card.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation patent application of U.S. patentapplication Ser. No. 16/526,814, filed Jul. 30, 2019 and titled“Electronic Card Having an Electronic Interface,” and this applicationis a continuation patent application of U.S. patent application Ser. No.16/526,880, filed Jul. 30, 2019 and titled “Electronic Card Having anElectronic Interface,” both of which are nonprovisional patentapplications of and claim the benefit of U.S. Provisional PatentApplication No. 62/737,528, filed Sep. 27, 2018 and titled “ElectronicCard Having an Electronic Interface,” U.S. Provisional PatentApplication No. 62/814,779, filed Mar. 6, 2019 and titled “ElectronicCard Having an Electronic Interface,” and U.S. Provisional PatentApplication No. 62/814,788, filed Mar. 6, 2019 and titled “ElectronicCard Having an Electronic Interface,” the disclosures of which arehereby incorporated herein by reference in their entireties.

FIELD

The described embodiments relate generally to electronic devices. Moreparticularly, the present embodiments relate to an electronic cardhaving an electronic interface and various features, as describedherein.

BACKGROUND

Traditionally, identification cards have been used to identify aparticular user or entity associated with the card. For example,identification cards may include a printed serial number, a photograph,or other information that can be used to identify a user. However,recent developments in user identification allow for electronic readersto identify a user by electronically reading an identification card orother form of ID. The cards, systems, and techniques described hereinare directed to electronic cards having improved features and processesfor manufacturing electronic cards.

SUMMARY

Embodiments described herein are directed to an electronicidentification card or an electronic card having various features. Theelectronic card may include an integrated circuit and a contact platefor electrically interfacing with the integrated circuit. The contactplate may include an array of terminal electrodes that are offset withrespect to the edges of the contact plate. The electronic card may becoated with a coating layer that extends at least partially over aferromagnetic element or film. The electronic card may also include ametal substrate having exposed chamfer portions that may provide avisual contrast to the coating layer and also improve the handling anduse of the electronic card.

In some example embodiments, the electronic identification card includesa substrate comprising a metal material. The substrate may define afirst recess or stepped region formed into a first surface of thesubstrate and extending along an outer substrate edge of the substrate.The substrate may also define a second recess formed into a secondsurface of the substrate, the second surface opposite to the firstsurface. A ferromagnetic film may be disposed at least partially withinthe first recess or stepped region and an integrated circuit may bedisposed at least partially within the second recess. The identificationcard also includes a coating layer comprising a polymer and a pigmentdispersed within the polymer. The coating layer may be disposed over theferromagnetic film and at least a portion of the substrate.

In some embodiments, the substrate is formed from a titanium sheethaving a thickness that is less than 1 mm. The substrate may include atitanium sheet that is bonded or laminated to a plastic (polymer) sheetand the combined thickness of the titanium sheet and the plastic sheetis less than 1 mm. In some cases, the first recess is a firstlaser-ablated recess formed into the first surface of the substrate. Thesecond recess may be a second laser-ablated recess formed into thesecond surface of the substrate. In some implementations, the electronicidentification card has a rectangular shape with four corners, eachcorner having a contoured shape. The contoured shape is a spline shapehaving a non-uniform radius of curvature.

In some embodiments, the coating layer comprises a first layer and asecond layer. The first layer comprises the polymer and the pigment, andthe second layer comprises a transparent polymer that is disposed overthe first layer and defines at least a portion of an external surface ofthe electronic identification card. In some cases, the coating layer isdisposed over the first surface and at least a portion of the secondsurface of the substrate.

In some embodiments, the electronic identification card also includes acontact plate positioned over the integrated circuit. The portion of theexternal surface defined by the transparent polymer may be a firstportion, and the contact plate may define an array of terminalelectrodes that define a second portion of the external surface of theelectronic identification card.

In some embodiments, the electronic identification card defines a firstset of chamfered edges that extends around the first surface, and asecond set of chamfered edges that extends around the second surface. Insome cases, a first chamfered edge of the first set of chamfered edgesextends along the outer substrate edge of the substrate. Theferromagnetic film may be attached to a backing layer and the firstchamfered edge may be defined, at least in part, by a beveled edgeformed within the ferromagnetic film and the backing layer. In someimplementations, the first chamfered edge does not extend beyond thebeveled edge of the ferromagnetic film and the backing layer.

In some embodiments, the second set of chamfered edges is defined, atleast in part, by a chamfer portion of the substrate. The electronicidentification card may also include an oxide coating formed over thechamfer portion of the substrate. The coating layer may have a firstcolor and the oxide coating may have a second color that is visuallydistinct from the first color.

In some embodiments, the electronic identification card furthercomprises a laser-formed relief feature. The laser-formed relief featuremay include at least one recess wall defining a recess extending throughthe coating layer. The laser-formed relief feature may also include arecessed marking feature defining a bottom of the recess and visuallydistinct from an adjacent portion of the coating layer.

Some example embodiments are directed to an electronic identificationcard including a substrate defining a recess formed into a front surfaceand an integrated circuit positioned in the recess. The electronic cardmay also include a ferromagnetic film positioned along a rear surface ofthe substrate that is opposite to the front surface. The electronic cardmay also include a contact plate positioned over the integrated circuitand may include: a plate substrate defining a set of outer edges, and anarray of terminal electrodes disposed over the plate substrate. Eachterminal electrode of the array of terminal electrodes may have arespective offset from the set of outer edges of the plate substrate.

In some implementations, the contact plate further comprises a set ofablated regions, each ablated region positioned between a respectiveterminal electrode of the array of terminal electrodes and a respectiveouter edge of the set of outer edges. In some cases, the contact platealso includes a conductive periphery portion that includes a conductivematerial that surrounds the array of terminal electrodes. The peripheryportion may be separated from the array of terminal electrodes by one ormore ablated regions.

In some implementations, the array of terminal electrodes may bedisposed over a front surface of the plate substrate. The contact platemay also include a rear conductive layer disposed over a rear surface ofthe plate substrate. The array of terminal electrodes may beelectrically coupled to the rear conductive layer by one or more viasthat extend through the plate substrate.

In some embodiments, the plate substrate is formed from a non-conductivematerial. The array of terminal electrodes may include a firstconductive layer including an electroless plated metal disposed over thenon-conductive material of the plate substrate. The array of terminalelectrodes may also include a second conductive layer including anelectroplated metal disposed over the first conductive layer.

Some example embodiments are directed to a method of forming a contactplate for an electronic card. A photoresist layer may be applied to afront surface of a plate substrate. The photoresist layer may be exposedusing a light source to form a plating mask defining an array of platingareas. A catalytic solution may be applied to the array of plating areasto form a first conductive layer along a plating area of the array ofplating areas. A plating solution may be applied to the first conductivelayer. While the plating solution is applied to the first conductivelayer, a second conductive layer may be formed over the first conductivelayer using an electroplating process that passes a current through thefirst conductive layer to define a terminal electrode having an offsetbetween the terminal electrode and an edge of the plate substrate.

In some embodiments, the plate substrate is formed from a non-conductivematerial. The first conductive layer may include a bridge portion thatelectrically couples the first conductive layer to the edge of the platesubstrate. In some cases, the method further comprises laser-ablating aportion of the first and second conductive layers that is located atleast partially within the bridge portion to expose a portion of thenon-conductive material of the plate substrate. In some embodiments, aconductive periphery portion is positioned over the front surface of theplate substrate and at least partially surrounds the terminal electrode.The bridge portion may extend between the terminal electrode and theconductive periphery portion.

In some embodiments, a rear conductive layer is formed along a rearsurface of the plate substrate, the rear surface being opposite to thefront surface. The first conductive layer may be electrically coupled tothe rear conductive layer using one or more vias that extend through theplate substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

The disclosure will be readily understood by the following detaileddescription in conjunction with the accompanying drawings, wherein likereference numerals designate like structural elements.

FIG. 1A depicts a front of an example electronic card.

FIG. 1B depicts a rear of an example electronic card.

FIG. 1C depicts an exploded view of an example electronic card.

FIG. 2 depicts an exploded view of an example electronic card.

FIGS. 3A-3C depict cross-sectional views of an electronic card.

FIG. 4 depicts a cross-sectional view of an electronic card.

FIGS. 5A-5C depict cross-sectional views of the electronic card.

FIGS. 6A-6D depict top views of example contact plates.

FIGS. 7A-7D depict various example arrays of terminal electrodes.

FIGS. 8A-8B depict example cross-sectional views of the example contactplate of FIG. 6.

FIGS. 9A-9B depict example connecting structures for a contact plate.

FIG. 10 depicts an example marking on an electronic card.

FIGS. 11A-11F depict cross-sectional views of an example marking on anelectronic card.

FIGS. 12, 13, and 14 depict example laser-formed relief features.

FIGS. 15A-15B depict example laser-formed relief features.

FIGS. 16A-16C depict example chamfers of an electronic card.

FIG. 17 depicts example components of an electronic card.

DETAILED DESCRIPTION

Reference will now be made in detail to representative embodimentsillustrated in the accompanying drawings. It should be understood thatthe following descriptions are not intended to limit the embodiments toone preferred embodiment. To the contrary, it is intended to coveralternatives, modifications, and equivalents as can be included withinthe spirit and scope of the described embodiments as defined by theappended claims.

The embodiments described herein are directed to an electronic cardhaving various features. As described herein, the electronic cardincludes an integrated circuit and an electronic interface that can beused to communicate with an external card reader. The electronic cardmay be an identification card used to authenticate or identify the user.In some examples, the electronic card is used as a security badge,employee identification card, student identification card, customerloyalty card, electronic passport, or some other form of electronicidentification. In some instances, the electronic card may be astate-issued identification card that serves as a driver's license,social security card, or other government-issued ID. The electronic cardmay also be used to facilitate a transaction or purchase and may, insome instances, be used as a credit card, debit card, prepaid debitcard, prepaid telephone card, vending card, parking card, toll card, andother similar types of card used to facilitate a transaction. In somecases, the electronic card is configured to securely store informationand/or a key or code that can be used to access securely storedinformation from another source. For example, the electronic card may beused to store or access medical records or financial information. Insome cases, the electronic card is configured to operate as a subscriberidentity module (SIM) for use with a mobile or cellular telephone. Theelectronic card may also be configured as a gift card that is configuredto store a card value or debit an account having the card value. Theelectronic card may also be used to provide access to a facility,restricted area, or restricted system. For example, the electronic cardmay include one or more components that are configured to communicatewith an external reader or device in order to unlock access to arestricted area, region, or system.

The electronic card, also referred to herein as an electronicidentification card, smart card, chip card, or integrated circuit card(ICC), typically includes an integrated circuit, an electricalinterface, and may also include one or magnetized elements like aferromagnetic strip or magnetic region. The electronic card may alsocomply with one or more standards including, for example, ISO 14443, ISO15693, ISO 7810, and/or ISO 7816 international standards. In someinstances, the electronic card may conform with standards and industrynorms related to what are referred to as “contact cards.” Contact cardstypically include an array of terminals or electrodes that make physicalcontact with an external card reader or other electronic device tofacilitate electronic communication. The electronic card may alsoconform with standards and practices that may be related to what arereferred to as “contactless cards.” In general, contactless cardsinclude a wireless transceiver or other wireless electronics that areconfigured to interface with an external device using a wirelesscommunication protocol. In some cases, contactless cards do include oneor more electrical contacts or terminals in addition to the wirelesselectronics and, in other cases, the contactless cards do not includeany electrical contacts or terminals. Whether the electronic card is acontact card or a contactless card, the electronic card may also includea magnetic or ferromagnetic strip for use with an external card readerhaving a magnetic swipe or similar magnetic strip reading functionality.

Some embodiments described herein are directed to an electronic cardhaving a metal substrate that is coated with a two-part coating ormulti-layer coating. The coating layer (made up of one or moreindividual layers or parts) may be specially formulated to give theelectronic card the appearance and/or tactile feel of a ceramicmaterial. For example, the coating layer may have a particularformulation of additives and a surface roughness that provides aceramic-like tactile feel to the touch. The coating layer may also beused to give the electronic card a uniform appearance and may concealdifferent functional elements of the card. For example, the coatinglayer may be used to conceal a ferromagnetic film, ferromagnetic strip,or ferromagnetic stack that is positioned below the coating. In someinstances, the ferromagnetic film, ferromagnetic strip, or ferromagneticstack is positioned in a stepped region, recess, or pocket formed intothe electronic card and then covered or coated by the coating layer.

Some embodiments described herein are directed to an electronic cardhaving a contact plate with a unique arrangement of electrodes. Inparticular, the electronic card may have a contact plate with an arrayof terminal electrodes that are offset from the edges of the contactplate. As described herein, the contact plate may have an array ofterminal electrodes where each terminal electrode is offset with respectto a respective edge of the contact plate. This configuration providescertain functional benefits by allowing a unique terminal layout thatmay not be possible using traditional techniques. However, thisconfiguration may also present various manufacturing challenges. Varioustechniques for solving these manufacturing challenges are describedherein. For example, in some examples, the terminal electrodes maytemporarily extend to one or more edges of the contact plate in order tofacilitate an electroplating process and then portions of the terminalelectrodes are ablated away using a laser-based process. In otherexamples, the terminal electrodes are electrically coupled to a copperlayer that is positioned on a hidden or inner surface of the contactplate, which may be used to facilitate an electroplating process.

Some embodiments described herein are directed to an electronic cardhaving a marking that is formed at least partially into the coatinglayer. In some embodiments, the marking includes a subsurface markingthat is formed below a first layer of a coating layer and into a secondlayer of a coating layer. In some embodiments, the marking includes alaser-relief feature that extends through the coating layer and exposesa portion of the underlying substrate. In examples where the substrateis formed from a metal material, the laser relief feature may includeone or more oxide layers that may provide a color or distinct visualappearance as compared to surrounding or adjacent portions of thecoating layer.

In some examples, the electronic card includes one or more chamfers orbeveled edges formed around the front or rear surface of the electroniccard. In some implementations, the chamfers or beveled edges are locatedentirely within a ferromagnetic film and support layer and do not extendinto an underlying metal substrate. In some cases, the chamfers orbeveled edges extend into the metal substrate to expose a portion of themetal material. In these cases, the exposed portion of the metalmaterial may be coated with an oxide layer that provides a differentcolor, distinct color, or particular visual appearance. In some cases,the chamfers include a coating or oxide layer that provides a coloredappearance and an edge of the card presents an exposed edge of the metalsubstrata that remains uncoated or uncovered by a coating or coloredoxide layer. Using these techniques allow for a distinctive visualappearance that is not as vulnerable to wear or degradation over time ascompared to a traditional ink or printed marking.

These and other embodiments are discussed below with reference to FIGS.1A-17. However, those skilled in the art will readily appreciate thatthe detailed description given herein with respect to these Figures isfor explanatory purposes only and should not be construed as limiting.

FIGS. 1A and 1B depict an example electronic card in accordance with theembodiments described herein. FIG. 1A depicts a front of the electroniccard 100. In general, the electronic card 100 may be an electronicidentification card that is associated with a specific individual. Theelectronic card 100 may be used to authenticate or identify theindividual or user. As suggested previously, the electronic card 100 maybe used as a security badge, employee identification card, studentidentification card, customer or retail loyalty card, electronicpassport, or some other form of electronic identification. Theelectronic card may also be used to facilitate a transaction or purchaseand may, in some instances, be used as a credit card, debit card,prepaid debit card, prepaid telephone card, vending card, parking card,toll card, and other similar types of card used to facilitate atransaction. The electronic card 100 may comply with one or morestandards including, for example, ISO 14443, ISO 15693, ISO 7810, and/orISO 7816 international standards.

In some cases, the electronic card 100 includes computer memory that isconfigured to securely store information and/or a key or code that canbe used to access information that is stored on an external device orsystem. For example, the electronic card 100 may be used to store oraccess medical records or financial information. In some cases, theelectronic card 100 is configured to operate as a subscriber identitymodule (SIM) for use with a mobile or cellular telephone on a wirelessor cellular network. The computer memory or computer-readable memoryfunctionality of the electronic card 100 may be provided by one or morememory components including, for example, electronically readablemagnetic strip or magnetic strap, programmable random access memory,solid state memory components, and other forms of electronic informationstorage components. Other example computer-readable memory componentsare described below with respect to FIG. 17.

The electronic card 100 may also be referred to as an electronicidentification card, smart card, chip card, or integrated circuit card(ICC). The electronic card 100 depicted in FIG. 1A is configured tooperate as a contact card. In some implementations, the electronic card100 may include wireless circuitry and may be configured to operate as acontactless card. If configured as a contactless card, the electroniccard 100 may still include the contact plate 102 or, alternatively, mayomit the contact plate 102.

As shown in FIG. 1A, the electronic card 100 includes several featuresalong the front surface 110. In particular, the electronic card 100includes a contact plate 102, which includes an array of terminalelectrodes 104 that define at least a portion of the external surface ofthe electronic card 100. The terminal electrodes 104 may be formed froma conductive material and may be configured to provide a contact-basedelectrical interface with an external device including, for example, anexternal card reader, terminal device, point of service (POS) system, orother similar type of device. As shown in FIG. 1A, the array of terminalelectrodes 104 may be offset from the edges of the contact plate 102 andmay have any one of a variety of shapes or configurations. Examplecontact plates and terminal electrodes are described below with respectto FIGS. 6A-9B.

In general, the terminal electrodes 104 of the contact plate 102 remainexposed to facilitate electrical contact with an external card reader ordevice. However, the terminal electrodes 104 may include a conductivecoating or otherwise be colored to substantially match the color of asurrounding portion of the electronic card 100. In one example, theterminal electrodes 104 are coated with a conductive ink or marking thatsubstantially matches a color of the coating of the electronic card 100in order to camouflage or hide the exposed terminal electrodes 104.While the contact plate 102 is depicted as having a square orrectangular form factor, in other embodiments, the contact plate 102 mayhave a circular or rounded profile or form factor. In some instances,the contact plate 102 and terminal electrodes 104, formed using one ofthe manufacturing techniques described, may be thinner than atraditional contact plate assembly or circuit.

As shown in FIG. 1A, the electronic card 100 may also include one ormore markings 114. The markings 114 may identify a company, institution,or entity associated with the electronic card 100. The markings 114 may,optionally, identify the user or individual associated with the card. Insome instances, the markings 114 may include an account number, serialnumber, or some other identifier associated with the individual and/orthe electronic card 100. In embodiments in which the electronic card 100is a credit card or other similar card issued by a financialinstitution, the electronic card 100 may omit the traditional signatureblock, expiration date, primary account number (PAN), or other moretraditional markings. The markings 114 may include a name and/or logo ofthe issuing entity and the card-holder's name or other uniquepersonalization associated with the card holder. Also, unlike sometraditional credit cards, the markings 114 may be flush, not embossed,or otherwise smooth along the exterior surface of the electronic card100.

In some cases, the markings 114 include a micro-scale security mark. Themicro-scale security mark may include micro-scale features that areetched, laser formed, machined, or otherwise formed into a coating ofthe electronic card 100. The micro-scale features may produce anauthenticating mark that is difficult to counterfeit or copy and may beused to verify the authenticity of the electronic card 100. In somecases, the micro-scale security mark may be integrated into one or morenon-micro-scale markings in order to camouflage or otherwise obscure theappearance of the micro-scale markings.

In some implementations, the markings 114 are printed or painted on thefront surface 110 of the electronic card 100. Additionally oralternatively, the markings 114 may be formed using a laser markingtechnique. In one example, the marking 114 is a subsurface markingformed into one of the coating layers of the electronic card 100. Inanother example, the markings 114 may include a laser-formed relieffeature that is formed into a coating or coating layer of the electroniccard 100 and may extend into an underlying card substrate. (See, e.g.,substrate 1202, 1302, and 1402 of FIGS. 12, 13, and 14, respectively.)Using a laser-formed relief feature as the marking 114 or as part of themarking 114 may provide a striking visual feature that is more durablethan a traditional ink or printed marking. A variety of example markingsare described below with respect to FIGS. 10-15B.

As shown in FIG. 1A, the electronic card 100 may include a set of edges116 that surround the front surface 110. In accordance with someembodiments described herein, one or more edges of the set of edges 116may include a chamfer or beveled region. In some embodiments, asdescribed herein, the set of edges 116 is a set of chamfered edges thatextends around or surrounds the front surface 110. The chamfer or bevelmay enhance the look and feel of the electronic card 100. The chamfer orbevel may also facilitate use of the electronic card 100 with respect tocertain external card readers or card-reading devices.

FIG. 1B depicts a rear of the electronic card 100. As shown in FIG. 1B,the electronic card 100 includes several features along the rear surface120. In particular, the electronic card 100 includes a set of edges 122that extends around or surrounds the rear surface 120. In accordancewith some embodiments described herein, one or more edges of the set ofedges 122 may include a chamfer or beveled region. The chamfer or bevelmay correspond to the chamfer or beveled region of the set of edges 116that surrounds the front surface 110. In particular, a second set ofchamfered edges may extend around or surround the rear surface 120. Asdescribed herein, the chamfered edges may be coated or covered with anoxide or other coating that provides a color along the chamfered edges.In some cases, the chamfered edges include exposed portions of the metalsubstrate. In some cases, the chamfered edges are colored and an edge orsidewall of the substrate that extends between the front and rearchamfered edges is exposed and remains uncoated or uncolored.

As shown in FIG. 1B, the electronic card 100 also includes a magneticregion 124. The magnetic region 124 may extend all the way to the edge122 a of the electronic card 100. In some embodiments, the magneticregion 124 is larger than a traditional magnetic strip used on atraditional credit card. The magnetic region 124 may allow encodedinformation to be read using an external card reader or card-readingdevice. While the entire magnetic region 124 may be encodable, in someimplementations, only a portion of the magnetic region 124 is actuallyencoded with information. For example, a sub-region within the magneticregion 124 may define an encoded strip or band that corresponds to thelocation of a traditional magnetic strip on a traditional credit card,identification card, or other card that is adapted to be read using anexternal magnetic reader. In one example, the encoded region of themagnetic region 124 is approximately 5-10 mm wide and offset from theedge 122 a by approximately 5 mm.

While the magnetic region 124 in FIG. 1B is depicted as extending allthe way to the edge 122 of the electronic card 100, in otherembodiments, the magnetic region 124 may be offset from one or more ofthe edges of the electronic card 100. Additionally, the orientation ofthe magnetic region 124 may vary in alternative embodiments. Forexample, the magnetic region 124 may be located along or offset withrespect to a short edge of the electronic card 100. In one alternativeembodiment, the magnetic region 124 is located within a central regionof the electronic card 100. In another alternative embodiment, themagnetic region 124 is omitted entirely.

As described below with respect to FIGS. 3A-3C, the magnetic region 124may be defined by a ferromagnetic film that is positioned below acoating layer. The coating layer may be thick enough to conceal theferromagnetic film while being thin enough to allow for the passage ofmagnetized signals or encoded data. While the ferromagnetic film oranother ferromagnetic element may be hidden or concealed by a coatinglayer, the electronic card 100 may include a visual marking 126 or otherindicia to indicate the approximate location of the ferromagneticelement or film and/or indicate a boundary or region of the magneticregion 124. The visual marking 126 may be formed using an ink orprinting technique and/or may include a recessed marking feature,similar to as described below with respect to FIGS. 10-15B.

As shown in FIGS. 1A and 1B, the electronic card 100 may include fourcorner regions 112. In this example the corner regions 112 have acontoured shape. In some implementations, the corner regions 112 have anon-uniform radius of curvature. Specifically, the corner regions 112may have a shape that corresponds to a splined or variable radiuscontour. Corner regions having a variable or non-uniform radius ofcurvature may be generally referred to as having a spline shape. In someimplementations, the corner regions 112 have a constant or uniformradius of curvature. In general, the corner regions 112 include arespective edge (of the set of edges 116, 122), which may be tangent toan adjacent edge along the respective surface. In some embodiments, therespective edge of each of the corner regions 112 has a bevel orchamfer, which may match the bevel or chamfer of the remaining edgesthat surround the respective surface (110, 120).

FIG. 1C depicts an exploded view of an example electronic card 100. Theelectronic card 100 may be formed from a metal substrate or othersubstrate material. In one example embodiment, the substrate is formedfrom a titanium or stainless steel material and the electronic card 100has a thickness that is less than a traditional credit card.Specifically, the thickness of the electronic card 100 may be less than0.75 mm. In addition, the flatness of the electronic card 100 may have aparticularly high degree of flatness. For example, the electronic card100 may have a flatness that varies less than 50 um across the area ofthe electronic card 100. In another example, the electronic card 100 mayhave a flatness that varies less than 20 um across the area of theelectronic card 100. In another example, the electronic card 100 mayhave a flatness that varies less than 10 um across the area of theelectronic card 100.

As shown in FIG. 1C, the electronic card 100 includes a recess 108formed into the front surface 110 of the electronic card 100. Anintegrated circuit 106 is positioned at least partially within therecess 108 and the contact plate 102 is positioned over the integratedcircuit 106. While the recess 108 is depicted as being approximatelysquare or rectangular in shape, in alternative embodiments, the recess108 may be circular or have a rounded shape or profile that isconfigured to receive a circular or rounded contact plate 102.

In some implementations, the integrated circuit 108 and the contactplate 102 are coupled (e.g., bonded) together to define a chip module105. The chip module 105 may be approximately 1 cm square. Inalternative embodiments, the chip module 105 may have a different shapeincluding a circular, oval, or rounded shape or profile. The area of thechip module 105 may be determined primarily by the area of the contactplate 102 which, in this case, are the same. The integrated circuit 106may include one or more processors, microprocessors, computer processingunits (CPUs), numeric processing units (NPUs), or other processingcircuitry. The integrated circuit 106 may also include one or more typesof computer memory including, for example, random-access memory (RAM),read-only memory (ROM), erasable programmable read-only memory (EPROM),or other types of non-transitory computer storage. In someimplementations, the integrated circuit 106 also includes wirelesscircuitry that is configured to transmit and/or receive wirelesscommunications or signals.

As shown in FIG. 1C, the electronic card 100 may also include a steppedregion 128 formed into the rear surface 120 of the electronic card 100.In the present example, the stepped region 128 extends all of the way tothe edge 122 a of the electronic card 100. However, in otherembodiments, the stepped region 128 may be offset inward from the edge122 a or another edge of the electronic card 100. In some instances, thestepped region 128 is defined by two parallel walls that extend alongthe length (or width) of the electronic card 100. As shown in FIG. 1C,the stepped region 128 is defined by a single wall that extends alongthe length of the electronic card 100.

As shown in FIG. 1C, a ferromagnetic stack, including a ferromagneticelement 130 (e.g., a ferromagnetic film) and a backing layer 132, ispositioned at least partially within the stepped region 128. The steppedregion 128 may also be referred to as a recess or pocket and may be alaser-ablated region formed using a laser-ablating or laser-machiningprocess. The stepped region 128 may also be formed using a mechanicalmachining or grinding process that removes a portion of the substrateusing a mechanical cutter or grinder. As shown in FIG. 1C, the steppedregion 128 includes a stepped surface that is recessed, relieved, orotherwise offset from an adjacent surface of the substrate or card.

As shown in FIG. 1C, the ferromagnetic stack, including theferromagnetic element 130 and the backing layer 132, extends all the wayto the edge 122 a of the electronic card 100. The stepped region 128 mayhave a depth that corresponds or is approximately equal to the thicknessof the ferromagnetic stack. Specifically, the stepped region 128 mayhave a depth that corresponds or is approximately equal to the thicknessof the ferromagnetic element 130 and the backing layer 132, combined.This allows for a flush or substantially smooth surface along the rearsurface 120 of the electronic card 100. For purposes of thisdescription, substantially smooth may be used to refer to a surface overwhich a transition, edge, or joint between two elements is not tactilelyperceptible. In accordance with some embodiments, some or all of theferromagnetic element 130 may be covered or coated with a coating layer,which may hide or conceal the ferromagnetic element 130.

In some cases, an exterior surface of the ferromagnetic stack istextured to provide a tactile or visual effect. For example, theferromagnetic element 130 and the backing layer 132 may be pressed orformed in order to produce a texture along an exterior surface of thecard. The texture may have a surface roughness that ranges between 0.3to 1.0 um Ra. In some cases, the ferromagnetic stack has a combinedthickness that is thinner than traditional magnetic strips. In somecases, the ferromagnetic stack has a thickness that ranges betweenapproximately 200 um and 270 um. In some cases, the ferromagnetic stackhas a thickness that ranges between approximately 225 um and 250 um.

In the example depicted in FIG. 1C, the ferromagnetic element 130 andbacking layer 132 are positioned within a recess or stepped region 128.However, in other embodiments, the ferromagnetic element 130 may bepositioned along an outer surface of the electronic card and a coatinglayer or another layer may be positioned adjacent to the ferromagneticelement 130 to define a substantially smooth transition, edge, or jointbetween the layer and the ferromagnetic element 130.

FIG. 2 depicts an exploded view of another example electronic card 200.Similar to the previous example, as shown in FIGS. 1A-1C, the electroniccard 200 includes a recess 208 formed into the front surface 210 of theelectronic card 200. A chip module 205 including an integrated circuit206 and a contact plate 202, may be positioned at least partially withinthe recess 208. In this example, the integrated circuit 206 ispositioned at least partially within the recess 208 and the contactplate 202 is positioned over the integrated circuit 206.

As shown in FIG. 2, the electronic card 200 includes a laminatedsubstrate that includes a first layer 201 and a second layer 203. In oneexample embodiment, the first layer 201 includes a metal or metallicsheet that is formed from aluminum, carbon steel, stainless steel,titanium, or other type of metal or metal alloy. The second layer 203may be formed from a polymer sheet (e.g., a plastic sheet) and adheredto the first layer 201 using an adhesive or other bonding agent. In somecases, the first layer 201 is laminated to the second layer 203 bypressing two sheets of material together and applying heat or elevatingthe temperature to create a bond between the two layers. While only twolayers are shown in this example, more than two layers may be used inother embodiments. For example, a plastic layer similar to the secondlayer 203 shown in FIG. 2 may be attached or adhered to the oppositeside (e.g., the front side) of the first layer 201. Thus, a first metallayer may be sandwiched or positioned between two or more polymer layers(plastic sheets) to form the electronic card 200.

As shown in FIG. 2, a ferromagnetic stack, including a backing layer 232and a ferromagnetic element 230 (e.g., a ferromagnetic film), may beattached to the substrate, which does not include a stepped region (incontrast to the example shown in FIG. 1C). In some cases, a thickness ofone or more coating or coating layers are deposited adjacent to theferromagnetic element 230 and the backing layer 232. If the one or morecoating or coating layers have a combined thickness that isapproximately equal to the combined thickness of the ferromagneticelement 230 and the backing layer 232, the interface, transition, orjoint between the ferromagnetic element 230 and the outer surface of theelectronic card 200 (formed by one of the coating or coating layers) maybe substantially smooth. In some embodiments, the ferromagnetic element230 is coated by an additional coating or coating layer that extendsacross the rear surface of the electronic card 200 and masks or obscuresthe ferromagnetic element 230 from view.

FIGS. 1A-1B and 2 depict example configurations and the position of thevarious elements may vary depending on the particular implementation.For example, in the example of FIGS. 1A-1B and 2, the ferromagneticstack or ferromagnetic element and the integrated circuit are positionedon opposite sides of the electronic card. However, in an alternativeembodiment, the recess and the stepped region are formed into the samesurface (e.g., the front surface) and the integrated circuit and theferromagnetic element may be positioned along the same side of theelectronic card. Furthermore, while in FIGS. 1A-1B and 2 the magneticregion extends along a longer side of the rectangular electronic card,in other implementations, the magnetic region may extend along one orboth shorter sides of the rectangular card. In some cases, the magneticregion may extend along two or more sides of the electronic card.Additionally, the location of the contact plate and correspondingintegrated circuit may vary depending on the implementation. In someembodiments, the electronic card may not include a contact plate, asdepicted in the examples of FIGS. 1A-1B and 2.

The examples of FIGS. 1A-1B and 2 depict electronic cards having aparticular shape or form factor. However, depending on theimplementation, the length, width, and/or the aspect of the length tothe width may vary from the general shapes depicted in FIGS. 1A-1B and2. In particular, the electronic card may have a width that is greaterthan a traditional credit card. In another example, the electronic cardmay have a length that is shorter than a traditional credit card.Similarly, the shape and size of the various elements including themagnetic region or magnetic element may be wider or otherwise vary indimension with respect to a magnetic strip of a traditional credit card.

FIGS. 3A-3C depict cross-sectional views of an electronic card 300 a,300 b, 300 c, which may correspond to section B-B of electronic card 100shown in FIG. 1B. As shown in FIG. 3A, the electronic card 300 aincludes a substrate 302 a that is coated with a coating or coatinglayer 333 a, 334 a. As described with respect to FIG. 3A and withrespect to other figures described herein, a coating layer may also bereferred to as a coating, a masking layer, or a masking. The descriptionof the coating layer 333 a, 334 a, substrate 302 a, ferromagneticelement 330 a, backing layer 333 a may extend to other embodimentsdescribed with respect to other figures and redundant description ofthese and other elements may be omitted for or abbreviated for clarity.

FIG. 3A depicts a cross-sectional view of a portion of the electroniccard 300 a having a magnetic region 324 a that may correspond to themagnetic region 124 of FIG. 1B. As shown in FIG. 3A, a ferromagneticstack including ferromagnetic element 330 a (e.g., a ferromagnetic film)at least partially defines the size and location of a magnetic region324 a. The ferromagnetic stack, including the ferromagnetic element 330a and the backing layer 332 a, are positioned within the stepped region328 a and have a combined thickness that is approximately equal to thedepth of the stepped region 328 a to create a substantially flush orsmooth interface along the rear surface 320 a of the electronic card 300a.

In this example, the stepped region 328 a is formed into a substrate 302a. In some implementations, the ferromagnetic element 330 a has athickness that is approximately 1 to 20 μm thick. In someimplementations, the ferromagnetic element 330 a has a thickness that isapproximately 3 to 10 μm thick. In some implementations, the backinglayer 332 a has a thickness that is approximately 50 to 150 μm thick. Insome implementations, the backing layer 332 a has a thickness that isapproximately 80 to 100 μm thick. In some implementations, the backinglayer 332 a is approximately 90 μm thick. The thickness of theferromagnetic stack including a combined thickness of the ferromagneticelement 330 a and the backing layer 332 a may range between 200 um and270 um.

The substrate 302 a, in this example and with regard to other examplesdescribed herein, may be formed from a single material or may be formedfrom multiple materials that are bonded or laminated together. Forexample, the substrate 302 a may be formed from a metal material (e.g.,a metal sheet) including, for example, aluminum, carbon steel, stainlesssteel, titanium, or other type of metal or metal alloy. The substrate302 a may also be formed from one or more polymers (e.g., a polymersheet or film) including, for example, polyvinyl chloride,polyethylene-based polymers, PVC, polyester, acrylic, styrene, orpolycarbonate. In some implementations, the substrate 302 a is formedfrom a composite material, which may include a filled polymer, carbonfiber, carbon laminate, or other structure formed from two or morematerials. In some cases, the substrate 302 a may be formed from aceramic, glass, or other similar type of material. The substrate 302 amay be formed as a unitary or homogenous element or, alternatively, maybe formed from a laminate of multiple materials or multiple layers(e.g., multiple sheets and/or films) that are bonded or adheredtogether. For example, the substrate 302 a may be formed from a metalsheet (e.g., titanium sheet) and bonded or laminated to one or morepolymer sheets (e.g., plastic sheets) to form a laminated multi-layersubstrate. In one example, the substrate 302 a includes a metal sheetthat is bonded to two plastic sheets, each plastic sheet bonded toopposite surfaces of the metal sheet. In another example, the substrate302 a includes a single plastic sheet that is bonded to a surface of themetal sheet. An adhesive or other bonding agent may be used to bondmultiple layers together.

The substrate 302 a may be formed from a sheet, plate, or multiplelayers having a combined thickness that is less than 1 mm. In somecases, the substrate 302 a has a combined or overall thickness that isapproximately 0.6 to 0.85 mm thick. In some instances, the electroniccard 300 a has an overall thickness that is less than 1 mm. In someinstances, the electronic card 300 a has an overall thickness that isapproximately 0.6 to 0.85 mm thick. In some instances, the electroniccard 300 a has an overall thickness that is approximately 0.5 to 0.75 mmthick.

As shown in FIG. 3A, a coating or coating layer 333 a may define atleast a portion of the front surface 310 a and a coating layer 334 a maydefine at least a portion of the rear surface 320 a. While coatinglayers 333 a, 334 a are designated with different item numbers, thecoating layers 333 a, 334 a may comprise a single continuous coatinglayer that defines at least a portion of both the front surface 310 aand the rear surface 320 a. In some cases, the coating layers 333 a, 334a may be generally referred to as a single layer, even though the edgesof the card may not be coated and the single layer is not continuous. Insome cases, the coating layers 333 a, 334 a each have a thickness ofless than 100 μm. In some implementations, the coating layers 333 a, 334a each have a thickness of between 50 μm and 10 μm. In someimplementations, the coating layers 333 a, 334 a have a thickness ofapproximately 60 μm.

In this example and in other examples described herein, the coatinglayers (333 a, 334 a) may be scratch resistant and/or chip resistant toprovide a durable coating for the electronic card. In some cases, thecoating layers are substantially stain resistant and may besubstantially impervious to staining or discoloration with normal use.As described herein, the coating layer or layers may have a hard coat orcoating layer that provides both structural durability and inhibitsdiscoloration of the electronic card for expected use of the electroniccard.

While coating layers 333 a, 334 a in FIG. 3A and in other figuresthroughout the disclosure may be depicted as being a single homogenousor unitary layer, the coating layers may be formed from multiple layersor regions. For example, as shown in the detail view, the coating layers333 a, 334 a may include a primer layer 352 positioned over a surface ofthe substrate 302 a, a first layer 354 formed over a surface of theprimer layer 352, and a second layer 356, including a hard coat ortransparent layer, formed over a surface of the first layer 354.

The first layer 354 may include one or more polymer materials. Whiledepicted as being a distinct and separate layer, in some instances, thefirst layer 354 includes the primer layer 352 that is adhered to asurface of the substrate 302 a. The first layer 354 may include one ormore additional urethane materials that are bonded or adhered to thesubstrate 302 a via the first urethane layer or primer layer 352. Theprimer layer 352 may be specially formulated to both adhere to a metalsubstrate (e.g., titanium, stainless steel) and adhere to the colorlayer or first layer 354 that may include a significant concentration ofa particular pigment like titanium oxide. The one or more additionalurethane materials may include a dual urethane or polyurethaneformulation that is applied to the first urethane layer or primer layer352.

In some implementations, the first layer 354 of the coating layers 333a, 334 a may be formed from a polymer material having a pigmentdispersed within the polymer material. The first layer 354 may also bereferred to herein as a polymer layer, color layer, and/or pigmentlayer. The pigment particles dispersed within the polymer layer may beinorganic pigment particles including, without limitation, metal oxidessuch as titanium oxides (TiO₂, Ti₂O₃), zinc oxides (ZnO), manganesedioxide (MnO₂), and iron oxides (Fe₃O₄). In some cases the pigmentincludes one or more of aluminum oxide, cobalt, copper, or other pigmentthat is suitable for use for a consumer product. The particles may havea size range of 0.1 μm to 10 μm or 0.1 μm to 1 μm. The polymer layer mayfurther comprise other additives.

In some cases, the coating layers 333 a, 334 a include a second layer356 that is formed over the first layer 354, such as a polymer layer,color layer, or pigment layer, which may include a polymer and pigment,as described above. In some cases, the second layer 356 may be atransparent layer that is transparent, translucent, and/or is formedfrom a transparent polymer. The transparent polymer may have a hardnessand/or an abrasion resistance greater than the underlying first layer.For example, the second layer 356 may comprise an acrylate polymer or anepoxy polymer. The second layer 356 may include a UV-curable materialthat is cured with exposure to a UV light source to create a hardenedexterior surface. The second layer 356 may also comprise fillermaterials, such as nanoscale inorganic or diamond materials. Nanoscalefiller materials may have a diameter less than 100 nm or less than 50nm. In some implementations, the second layer 356 comprises adiamond-like carbon (DLC) coating or other similar coating material. Forexample, the second layer 356 of the coating layers 333 a, 334 a mayinclude a tetrahedral amorphous carbon material having a thickness thatranges from 1 μm to 50 μm.

The coating layers 333 a, 334 a, including their constituent componentsor sublayers, may be deposited on the substrate 302 a using a depositionor layer application process. Example deposition or layer applicationprocesses include physical vapor deposition (PVD), atomic depositioncoating (ALD), spray coating, dip coating, and other similar materialdeposition processes. Each layer or sublayer of the coating layers 333a, 334 a may be applied using a separate deposition process, dependingon the type of layer or sublayer that is being applied.

The ferromagnetic element 330 a may be formed from a film of materialthat is capable of magnetically storing or maintaining encoded data orother information. The encoded data or other information may be readusing an external card reader or card-reading device. The ferromagneticelement 330 a may include a film or thin layer of metal or metalizedmaterial that is configured to hold or maintain a magnetic field. Insome cases, the ferromagnetic element 330 a is formed from a nickel,iron, ferrite, steel, cobalt, or other ferromagnetic material. Theferromagnetic element 330 a may be deposited on, laminated to, orotherwise adhered or attached to the backing layer 332 a. In someimplementations, the ferromagnetic element 330 a is deposited (e.g.,sputtered, printed, coated) onto the backing layer 332 a.

The backing layer 332 a may be formed from one or more of a polymer,metal, or other suitable materials and may include an adhesive orbonding agent. In one example, the backing layer 332 a includes two ormore polycarbonate sheets that are bonded or otherwise adhered together.In one implementation, the backing layer 332 a includes a firstpolycarbonate sheet that is colored white and a second polycarbonatesheet that is transparent or clear. The two or more polycarbonate sheetsmay be bonded to the substrate 302 a by a thermoset adhesive. In anotherexample, the backing layer 332 a may include or comprise apressure-sensitive adhesive (PSA) on one or both surfaces of the backinglayer 332 a to facilitate attaching the ferromagnetic element 330 a tothe substrate 302 a. In another example, the backing layer 332 a isformed from one or more polymer materials (e.g., polycarbonate sheets)and includes an adhesive on one or more sides. The polymer material ofthe backing layer 332 a may also be bonded to the substrate 302 a usinga heat bonding or heat lamination process that does not use a separateadhesive layer.

The ferromagnetic stack may be processed in order to provide aparticular texture. The texture may provide a desired appearance and/orhand feel that corresponds to a texture of other portions of theelectronic card 300 a. For example, the ferromagnetic stack may beformed from two or more polycarbonate sheets that are bonded to aferromagnetic film. The ferromagnetic stack may be pressed with a heatedtexture plate that impresses a texture into an exterior surface of theferromagnetic stack. In some cases, the impressed texture has a surfaceroughness that ranges between 0.3 to 1.0 um Ra. In one example, theimpressed texture has a surface roughness that is approximately 0.5 umRa or greater.

The examples described herein may be used to form a ferromagnetic stackthat is thinner than some traditional magnetic strips. In someimplementations, the ferromagnetic element 330 a has a thickness thatranges from 0.005 mm to 0.05 mm and the backing layer 332 a has athickness that ranges from 0.05 mm to 1.5 mm. The thickness of theferromagnetic stack including a combined thickness of the ferromagneticelement 330 a and the backing layer 332 a may range between 200 um and270 um.

FIG. 3B depicts an example electronic card 300 b having chamfer featuresor chamfered edges. The electronic card 300 b may include elements andfeatures as described herein with respect to other electronic cardembodiments, the descriptions of which are omitted for clarity. As shownin FIG. 3B, the electronic card 300 b includes chamfered edges 310 b and312 b (example chamfer features) formed along the edge of the electroniccard 300 b. While FIG. 3B depicts example chamfered edges 310 b and 312b, the electronic card 300 b may include chamfered edges that extendalong all of the outer edges of the card (e.g., along the set of edges116 of FIG. 1A and the set of edges 122 of FIG. 1B).

In this example the chamfered edge 310 b is defined, at least in part,by a beveled region formed within the ferromagnetic element 330 b andthe backing layer 332 b. As shown in FIG. 3B, the chamfered edge 310 bdoes not extend beyond the beveled edge of the ferromagnetic element 330b and the backing layer 332 b. Thus, the chamfered edge 310 b isdefined, at least in part, by the beveled edge formed within theferromagnetic element 330 b and the backing layer 332 b. Stated anotherway, the beveled edge of the ferromagnetic element 330 b and the backinglayer 332 b ends at a (vertical) sidewall 314 or edge of the substrate302 b. In general, the sidewall 314 is approximately perpendicular tothe surfaces 320 a and 310 b, as shown in FIG. 3B.

As shown in FIG. 3B, the electronic card 300 b includes coating layers333 b, 334 b that extend over at least a portion of the front surface310 b and the rear surface 320 b of the electronic card 300 b. Asdescribed above with respect to FIG. 3A and other embodiments herein,the coating layers 333 b, 334 b may be formed from multiple layers.Specifically, the coating layers 333 b, 334 b may include a first layerthat includes a polymer and pigment dispersed within and a second, outerlayer formed over the first layer. The second or outer layer may includea transparent polymer and/or a diamond-like carbon (DLC) coating. Asdiscussed previously, while the coating layers 333 b, 334 b aredesignated in FIG. 3B by two item numbers, the coating layers 333 b, 334b may be formed from a single continuous or coating layer.

FIG. 3C depicts another example electronic card 300 c. The electroniccard 300 c may include elements and features as described herein withrespect to other electronic card embodiments, the descriptions of whichare omitted for clarity. FIG. 3C depicts an electronic card 300 c havingcoating layers 333 c, 334 c that extend over substantially all or nearlyall of the front and rear surfaces of the electronic card 300 c. Asshown in FIG. 3C, the coating layer 334 c extends over the rear surfaceincluding over the ferromagnetic stack including the ferromagneticelement 330 c and backing layer 332 c. As discussed previously, theferromagnetic stack may define the magnetic region of the electroniccard 300 c (see, for example, region 124 of FIG. 1B). By extending thecoating layer 334 c over the ferromagnetic element 330 c, theferromagnetic element 330 c may be concealed from view. In some cases,the coating layer 334 c may provide a continuous and/or uniform visualappearance across a transition between the magnetic region and adjacentor surrounding regions of the electronic card 300 c. While the coatinglayer 334 c may conceal the transition between the ferromagnetic element330 c and an adjacent portion of the electronic card 300 c, there may beadditional markings or indicia that are formed on or into the coatinglayer 334 c and that indicate an approximate location of the magneticregion or edge of the ferromagnetic element 330 c and/or a boundary ofan encoded region within a magnetic region defined by the ferromagneticelement 330 c.

In general, the coating layer 334 c is configured to pass magneticsignals and/or magnetically encoded information that is stored orencoded on the ferromagnetic element 330 c. Specifically, the coatinglayer 334 c may be formed from a dielectric or non-conductive materialand may be thin enough to allow reliable communication between theferromagnetic element 330 c and an external card reader or card-readingdevice. In some instances, the coating layer 334 c is approximately 60μm or less in thickness. In some instances, the coating layer 334 c isapproximately 30 μm or less in thickness. In some instances, the coatinglayer 334 c is approximately 20 μm or less in thickness.

The coating layer 334 c typically includes at least one layer or regionthat includes a pigment dispersed within the coating layer 334 c to helpconceal or mask the underlying substrate 302 c and/or ferromagneticelement 330 c. The thickness of the coating layers 333 c, 334 c maydepend, at least in part, on the color of the pigment. For example,darker pigments may be able to conceal underlying elements or componentswith thinner coating than lighter or white pigments.

As discussed above with respect to FIG. 3A, the coating layer 334 c mayalso include an outer layer or coating that may have a hardness thatresists wear and/or scratches. In some cases the outer layer is atransparent polymer, such as an acrylic (e.g., acrylate polymer) or anepoxy (e.g., epoxy polymer). In some cases, the coating layer 334 cincludes a UV-curable polymer. In some cases, the outer layer or coatingincludes a diamond-like carbon (DLC) coating. The thickness of the DLCcoating may range from approximately 1 μm to 50 μm.

As shown in FIG. 3C, the coating layer 334 c, the ferromagnetic stack,including the ferromagnetic element 330 c and the backing layer 332 c,at least partially defines the chamfered edge 310 c. Similarly, coatinglayer 333 c and the substrate 302 c at least partially define thechamfered edge 312 c. As discussed previously, while the coating layers333 c, 334 c are designated in FIG. 3C by two item numbers, the coatinglayers 333 c, 334 c may be formed from a single continuous or coatinglayer. The coating layers 333 c, 334 c may also be referred to as asingle layer even though the coating layer does not extend around theedges of the card and is a discontinuous layer from the front to theback of the electronic card 300 c.

FIG. 4 depicts another example electronic card 400. The electronic card400 may include elements and features as described herein with respectto other electronic card embodiments, the descriptions of which areomitted for clarity. FIG. 4 depicts an electronic card 400 havingcoating layers 433, 434 that extend over substantially all or nearly allof the front and rear surfaces of the electronic card 400. Thecross-sectional view of FIG. 4 corresponds to the configuration of FIG.2 in which the ferromagnetic element 230 and the backing layer 232 arenot positioned within a recess or groove. As shown in FIG. 4, thecoating layer 434 extends over the rear surface including over theferromagnetic element 430 of the magnetic region (see, e.g., region 124of FIG. 1B). By extending the coating layer 434 over the ferromagneticelement 430, the ferromagnetic element 430 may be concealed from view.As shown in FIG. 4, the coating layer 434 does not have a uniformthickness in order to accommodate the thickness of the ferromagneticelement 430 and the backing layer 432.

Similar to the previous example, the coating layer 434 may provide acontinuous and/or uniform visual appearance across a transition betweenthe magnetic region and adjacent or surrounding regions of theelectronic card 400. While the coating layer 434 may conceal thetransition between the ferromagnetic element 430 and an adjacent portionof the electronic card 400, there may be additional markings or indiciathat are formed on or into the coating layer 434 and that indicate anapproximate location of the magnetic region or edge of the ferromagneticelement 430 and/or a boundary of an encoded region within a magneticregion defined by the ferromagnetic element 430.

In general, at least a portion of the coating layer 434 is configured topass magnetic signals and/or magnetically encoded information that isstored or encoded on the ferromagnetic element 430. Specifically, thecoating layer 434 may be formed from a dielectric or non-conductivematerial and may be thin enough to allow reliable communication betweenthe ferromagnetic element 430 and an external card reader orcard-reading device. In some instances, the coating layer 434 isapproximately 60 μm or less in thickness in a region that extends overthe ferromagnetic element 430. In some instances, the correspondingregion of the coating layer 434 is approximately 30 μm or less inthickness. In some instances, the corresponding region of the coatinglayer 434 is approximately 20 μm or less in thickness.

Similar to previous examples, the coating layer 434 typically includesat least one layer or region that includes a pigment dispersed withinthe coating layer 434 to help conceal or mask the underlying substrate402 and/or ferromagnetic element 430. The thickness of the coatinglayers 433, 434 may depend, at least in part, on the color of thepigment. For example, darker pigments may be able to conceal underlyingelements or components with thinner coating than lighter or whitepigments.

As discussed above with respect to FIGS. 3A and 3C, the coating layer434 may also include an outer layer or coating that may have a hardnessthat resists wear and/or scratches. In some cases the outer layer is atransparent polymer, such as an acrylic (e.g., acrylate polymer) or anepoxy (e.g., epoxy polymer). In some cases, the coating layer 434includes a UV-curable polymer. In some cases, the outer layer or coatingincludes a diamond-like carbon (DLC) coating. The thickness of the DLCcoating may range from approximately 1 μm to 50 μm.

As shown in FIG. 4, the coating layer 434, the ferromagnetic element 430and the backing layer 432 at least partially define the chamfered edge410. Similarly, coating layer 433 and the substrate 402 at leastpartially define the chamfered edge 412. As discussed previously, whilethe coating layers 433, 434 are designated in FIG. 4 by two itemnumbers, the coating layers 433, 434 may be formed from a singlecontinuous or coating layer.

FIG. 5A depicts a cross-sectional view of an electronic card 500 a. Thecross-sectional view may correspond to the section A-A indicated on FIG.1A. As shown in FIG. 5A, the electronic card 500 a includes anintegrated circuit 506 a positioned at least partially within the recess508 a formed into the substrate 502 a of the electronic card 500 a. Thecontact plate 503 a is positioned over the integrated circuit 506 a andis also at least partially disposed in the recess 508 a. The integratedcircuit 506 a and/or the contact plate 503 a may be coupled orintegrated to define a chip module that is approximately 1 cm square.The dimensions of the integrated circuit 506 a and/or the contact plate503 a may vary depending on the implementation and they may have arectilinear shape having a width and length that ranges between 0.5 cmto 2 cm. It is not necessary that the length and width be equal orsubstantially equal. In some instances, the integrated circuit 506 aand/or the contact plate 503 a are circular or rounded in shape orprofile.

As shown in FIG. 5A, the contact plate 503 a includes an array ofterminal electrodes 504 a that are exposed and define at least a portionof an external surface of the electronic card 500 a. The depth of therecess 508 a and/or the thickness of the integrated circuit 506 a andcontact plate 503 a may be configured to provide a substantially smoothor flush surface along the front of the electronic card 500 a. In someimplementations, the array of terminal electrodes 504 a protrudeslightly from the front surface of the electronic card 500 a in order tofacilitate physical and electrical connection with an external cardreader or card-reading device. As shown in FIG. 5A, the front and rearsurfaces of the electronic card 500 a may be defined, at least in part,by the coating layers 532 a and 534 a.

As shown in FIG. 5A, the contact plate 503 a may be attached to thesubstrate 502 a by adhesive 548 a. The adhesive 548 a may include apressure-sensitive adhesive, an epoxy adhesive, a hot-melt bondingmaterial, or some other type of adhesive material or component. In thepresent example, the contact plate 503 a is attached to a shelf regionformed within the recess 508 a. By attaching the contact plate 503 a toa shelf region, the combined thickness of the adhesive 548 a and thecontact plate 503 a may be more easily controlled or predicted toprovide a more consistent or uniform location of the array of terminalelectrodes 504 a with respect to the exterior surface of the electroniccard 500 a.

In some implementations, the shelf region and/or a surface of thecontact plate 503 a are textured or otherwise prepared to promoteadhesion to the adhesive 548 a. For example, the shelf region of therecess 508 a may be textured with a laser to create small surfacefeatures that improve the bonding between the shelf region of the recess508 b and the adhesive 548 a. In some cases, the surface is ablated witha laser to create micro-sized features that increase the bonding surfacearea and also improve the bonding strength between the recess 508 b andthe adhesive 548 a. In some embodiments, a laser-based process is usedto ablate the surface of the shelf region and produce a surfaceroughness of approximately 1.0 um Ra, which may increase the bondstrength between the substrate 502 a and the adhesive 548 a. In somecases, a laser-based process is used to produce a surface roughness thatranges between 0.5 um and 2 um Ra. In some instances, the shelf regionof the recess 508 a is textured using a mechanical texturing processand/or chemical texturing process that produces the desired surfaceroughness.

The surface of the shelf region of the recess 508 a may also be coatedwith a color layer or coloring agent to produce a black or dark coloralong the shelf region. This may help with the cosmetic appearance ofthe transition between the contact plate 503 a and the surroundingportions of the electronic card 500 a. While these features and bondingtechniques are described with respect to the electronic card 500 a ofFIG. 5A, the same techniques may be applied to other embodimentsincluding those shown in FIGS. 5B and 5C.

The recess 508 a and/or the adhesive 548 a may also include one or moreventing features that allow gas or vapors to escape the recess 508 aduring manufacturing or other situations. For example, small grooves maybe formed into the shelf region and/or the adhesive 548 a to allow hotgas or vapor to exit the recess 508 a. In one implementation, the shelfregion defines a groove ranging between 0.5 mm and 1 mm square to allowfor the passage of gas or vapors. Additionally or alternatively, theadhesive 548 a may include a gap ranging between 0.5 mm and 1 mm toallow for the passage of gasses or vapors. The venting features may helpgasses or vapors escape during a heated bonding or lamination process inwhich heat is applied to one or more surfaces of the electronic card 500a. In some cases, the venting features defined into the adhesive and/orthe recess may facilitate a higher temperature bonding or manufacturingprocess. While the venting features are described with respect to theelectronic card 500 a of FIG. 5A, the same techniques may be applied toother embodiments including those shown in FIGS. 5B and 5C.

In the example of FIG. 5A, the integrated circuit 506 a includes asemiconductor 542 a embedded in an encapsulate portion 544 a. Thesemiconductor 542 a may be electrically coupled to one or more of thearray of terminal electrodes 504 a. In the present example, thesemiconductor 542 a of the integrated circuit 506 a is coupled to thearray of terminal electrodes 504 a by one or more respective vias orconductive elements 546 a. In some cases, the vias or conductiveelements 546 a are integrally formed into the contact plate 503 a anddefine terminals that are soldered to the integrated circuit 506 a. Theencapsulate portion 544 a may be formed from a dielectric material andmay provide structural support and electrical insulation for theintegrated circuit 506 a.

While a simplified example is depicted in FIG. 5A, the integratedcircuit 506 a and/or the contact plate 503 a may include additionalcomponents or elements not expressly depicted in FIG. 5A. For example,the electronic card 500 a may also include an antenna and/or wirelesscommunication circuitry that are configured to facilitate wirelesscommunication with an external device, such as a card reader havingwireless functionality or capability. In some instances, the integratedcircuit 506 a includes an antenna and/or wireless communicationcircuitry that is configured to wirelessly communicate with an externaldevice. If the integrated circuit 506 a and/or the electronic card 500 aare configured to conduct wireless communications with an externaldevice, the contact plate 503 a may be omitted or optional.

In general, the integrated circuit 506 a is configured to provideelectronic functionality for the electronic card 500 a. In particular,the integrated circuit 506 a may include a microcontroller or other typeof processing unit that is configured to perform a particular set offunctions. For example, if the electronic card 500 a is configured tofacilitate a financial transaction, the integrated circuit 506 a may beconfigured to store and/or produce a security code that is used toauthenticate a user or transaction. In some cases, the integratedcircuit 506 a may be configured to provide a unique identification orserial number that may be associated with a user, a user's account, apromotion, a merchant, or some other entity or institution. As discussedin more detail below with respect to FIG. 17, the integrated circuit 506a may include other elements or components including, for example,non-volatile computer memory, computer processing units (CPUs),numerical processing units (NPUs), wireless communication circuitry, orother electronic elements, components, or systems.

FIG. 5A may represent a cross-sectional view of a chip module having acontact plate that is similar to the contact plate 602 a of FIG. 6Ataken along section C-C. Specifically, the contact plate 503 a and thecontact plate 602 a both include a center electrode (504 a, 620 a) thatis electrically coupled to the integrated circuit 506 a by a via 546 a.However, in an alternative arrangement, one or more of the electrodesmay not be electrically coupled to the integrated circuit 506 a and maybe cosmetic in nature.

FIG. 5B depicts an alternate arrangement in which a center electrode 504b or center portion is not coupled to the semiconductor 542 b of theintegrated circuit 506 b. The arrangement depicted in FIG. 5B maycorrespond to the contact plate 602 b of FIG. 6B taken along sectionD-D. As shown in FIG. 5B, the center portion 504 b and peripheralportions are not coupled to the semiconductor 542 b of the integratedcircuit 506 b. The left and right electrodes 504 b are electricallycoupled to the semiconductor 542 b by a respective conductor 543 b,which may include a wire or other conductive conduit. The semiconductor542 b, the conductor 543 b and at least a portion of the via 546 b maybe encapsulated by the encapsulate portion 544 b.

As shown in FIG. 5B, the electronic card 500 b includes coating layers532 b, 534 b that are formed over respective surfaces of the substrate502 b. Similar to the previous example, the contact plate 503 b iscoupled to a recess 508 b by adhesive 548 b, which may be positionedalong a ledge or shelf of the recess 508 b. The description of thevarious elements are provided above with respect to previous figures andalso apply to the configuration of FIG. 5B. In particular, the recess508 b may include venting features to facilitate the release of gassesor vapors and a shelf portion of the recess 508 b may be textured topromote bonding with the adhesive 548 b.

FIG. 5C depicts another alternate arrangement in which a centerelectrode 504 c or center portion is not coupled to the semiconductor542 c of the integrated circuit 506 c. Furthermore, the arrangementdepicted in FIG. 5C includes terminal electrodes 507 c that extendaround an edge of the contact plate 503 c. In this example, the terminalelectrodes 507 c are electrically coupled to the semiconductor 542 c bya conductive conduit 543 c. The semiconductor 542 c, the conductiveconduit 543 c and at least a portion of the terminal electrode thatextends along the bottom surface of the contact plate 503 c may beencapsulated by the encapsulate portion 544 c. The arrangement depictedin FIG. 5C may correspond to the contact plate 602 c of FIG. 6C.Specifically, the portion of the terminal electrode 507 c that wrapsaround the contact plate 503 c in FIG. 5C may correspond to theconnector portion 656 c of terminal electrode 652 c in FIG. 6C.

As shown in FIG. 5C, the electronic card 500 c includes coating layers532 c, 534 c that are formed over respective surfaces of the substrate502 c. Similar to the previous example, the contact plate 503 c iscoupled to a recess 508 c by adhesive 548 c, which may be positionedalong a ledge or shelf of the recess 508 c. The description of thevarious elements are provided above with respect to previous figures andalso apply to the configuration of FIG. 5C. In particular, the recess508 c may include venting features to facilitate the release of gassesor vapors and a shelf portion of the recess 508 c may be textured topromote bonding with the adhesive 548 c.

FIG. 6A depicts a top view of an example contact plate 602 a. Thecontact plate 602 a may correspond to the contact plates described abovewith respect to FIGS. 1A, 1C, 1D, and 5A. The contact plate 602 aincludes a plate substrate 610 a and an array of terminal electrodes 612a, 614 a, 616 a, 618 a, 620 a, 622 a, 624 a, 626 a, 628 a that arepositioned along a front or outer surface of the plate substrate 610 a.The terminal electrodes 612 a, 614 a, 616 a, 618 a, 620 a, 622 a, 624 a,626 a, 628 a are formed from a conductive material and each defines aportion of an exterior surface of the electronic card and may be exposedto facilitate physical contact and electrical connection with anexternal device, such as an external card reader or card-reading device.In some cases, the terminal electrodes 612 a, 614 a, 616 a, 618 a, 620a, 622 a, 624 a, 626 a, 628 a may be formed from a copper, nickel,platinum, carbon, silver, gold, alloy, or other conductive material.

In general, the plate substrate 610 a defines a set of outer edges thatform the profile or perimeter of the plate substrate 610 a. As shown inFIG. 6A, each of the terminal electrodes 612 a, 614 a, 616 a, 618 a, 620a, 622 a, 624 a, 626 a, 628 a is separated or offset from an edge (ofthe set of outer edges) of the plate substrate 610 a. Specifically, asshown in FIG. 6A, the contact plate 602 a includes a perimeter portion630 a that surrounds the array of terminal electrodes 612 a, 614 a, 616a, 618 a, 620 a, 622 a, 624 a, 626 a, 628 a such that each of theterminal electrodes 612 a, 614 a, 616 a, 618 a, 620 a, 622 a, 624 a, 626a, 628 a is offset from the nearest edge by the width of a respectivesegment of the perimeter portion 630 a. While the perimeter portion 630a depicted in FIG. 6A appears to have a substantially uniform width, inother implementations, the width may vary or have a non-uniform width.For example, a top or bottom segment of the perimeter portion 630 a maybe greater than or less than a side segment of the perimeter portion 630a. Similarly, the top segment of the perimeter portion 630 a may have awidth that is different than a bottom segment, and so on.

In FIG. 6A, each of the terminal electrodes 612 a, 614 a, 616 a, 618 a,620 a, 622 a, 624 a, 626 a, 628 a may be configured to provide anelectrical connection for a particular function of the electronic card.By way of example, a first terminal electrode 612 a may provide adedicated power terminal (e.g., a VCC terminal), a second terminalelectrode 614 a may provide a dedicated reset signal terminal (e.g., aRST terminal), a third terminal electrode 616 a may provide a dedicatedclock signal terminal (e.g., a CLK terminal), a fourth terminalelectrode 618 a may provide an auxiliary or programmable terminal, afifth terminal electrode 620 a may provide an auxiliary or programmableterminal, a sixth terminal electrode 622 a may provide a dedicatedground terminal (e.g., a GND terminal), a seventh terminal electrode 624a may provide a dedicated programming terminal (e.g., a VPP terminal),and the eighth and ninth terminal electrodes 626 a and 628 a may providean auxiliary or programmable terminal.

FIGS. 6B, 6C, and 6D depict alternative electrode arrangements for acontact plate. In particular, the contact plates 602 b, 602 c, and 602 dall include a peripheral portion 630 b, 630 c, 630 d that are at leastpartially coated with a conductive material. The conductive material ofthe peripheral portions 630 b, 630 c, 630 d may be the same or a similarmaterial that is used to form the terminal electrodes 642 b, 652 c, 662d. In some cases, the peripheral portions 630 b, 630 c, 630 d and theterminal electrodes 642 b, 652 c, 662 d are formed from one or more ofthe same layers and are then separated by forming voids or grooves 644b, 654 c, 664 d within the one or more layers to electrically isolatethe terminal electrodes 642 b, 652 c, 662 d from other portions of theone or more layers that form the peripheral portions 630 b, 630 c, 630d.

In FIG. 6B, the terminal electrodes 642 b are separated from theperipheral portion 630 b by a void or groove 644 b. The void or groove644 b electrically isolates each respective terminal electrode 642 bfrom other conductive elements along the upper surface of the contactplate 602 b. In some cases, the grooves 644 b expose portions of theplate substrate 610 b. Similar to the previous example, the terminalelectrodes 642 b are offset with respect to the respective edges of theplate substrate 610 b. The contact plate 602 b of FIG. 6B may correspondto the cross-sectional view depicted in FIG. 5B.

Similar to the previous example, in FIG. 6C, the terminal electrodes 652c are separated from the peripheral portion 630 c by a void or groove654 c. The void or groove 654 c electrically isolates each respectiveterminal electrode 652 c from other conductive elements along the uppersurface of the contact plate 602 c. In some cases, the grooves 654 cexpose portions of the plate substrate 610 c. As shown in FIG. 6C, theterminal electrodes 652 c each include a connector portion 656 c thatmay extend around the edge of the plate substrate 610 c to electricallyconnect to an integrated circuit or other electrical component. Thecontact plate 602 c of FIG. 6C may correspond to the cross-sectionalview depicted in FIG. 5B or 5C.

In FIG. 6D, the terminal electrodes 662 d are separated from theperipheral portion 630 d by a void or groove 664 d. The void or groove664 d electrically isolates each respective terminal electrode 662 dfrom other conductive elements along the upper surface of the contactplate 602 d. In some cases, the grooves 664 d expose portions of theplate substrate 610 d. As shown in FIG. 6D, the contact plate 602 d alsoincludes an outer peripheral portion 666 d that surrounds the peripheralportion 630 d. The outer peripheral portion 666 d may not be coated by aconductive coating. In some cases, the outer peripheral portion 666 dincludes an exposed surface of the plate substrate 610 d. The contactplate 602 d of FIG. 6D may correspond to the cross-sectional viewdepicted in FIG. 5A.

FIGS. 7A-7D depict various example arrays of terminal electrodes.Specifically, FIG. 7A depicts an example contact plate 702 a having anarray of terminal electrodes 704 a that are rectangular in shape. Asshown in FIG. 7A, the terminal electrodes 704 a are disposed on an outeror upper surface of a plate substrate 710 a and are offset from theedges of the plate substrate 710 a by a gap or space. Specifically, thearray of terminal electrodes 704 a are at least partially surrounded bya perimeter region 730 a. In the current example, none of the electrodesof the array of terminal electrodes 704 a extend to an edge of thecontact plate 702 a. However, in alternative embodiments, one or more ofthe electrodes of the array of terminal electrodes 704 a may extend to arespective edge of the contact plate 702 a.

FIG. 7B depicts an example contact plate 702 b having an array ofterminal electrodes 704 b having a square or rectangular shape. Similarto the previous example, the array of terminal electrodes 704 b aredisposed on a plate substrate 710 b and are offset or spaced apart fromthe edges of the plate substrate 710 b. As shown in FIG. 7B, the arrayof terminal electrodes 704 b are at least partially surrounded by aperimeter region 730 b of the plate substrate 710 b.

FIG. 7C depicts an example contact plate 702 c having an array ofterminal electrodes 704 c having an elongated shape with roundedcorners. Similar to the previous examples, the array of terminalelectrodes 704 c are disposed along or on a plate substrate 710 c andare offset or spaced apart from the edges of the plate substrate 710 c.As shown in FIG. 7C, the array of terminal electrodes 704 c are at leastpartially surrounded by a perimeter region 730 c of the plate substrate710 c.

FIG. 7D depicts an example contact plate 702 d having an array ofterminal electrodes 704 d having a diamond shape. Similar to theprevious examples, the array of terminal electrodes 704 d are disposedon a plate substrate 710 d and are offset or spaced apart from the edgesof the plate substrate 710 d. As shown in FIG. 7D, the array of terminalelectrodes 704 d are at least partially surrounded by a perimeter region730 d of the plate substrate 710 d.

The terminal electrode configurations depicted in FIGS. 7A-7D areprovided by way of example and are not intended to be an exhaustivedescription of all possible configurations. For example, it is notrequired that the electrodes of an array of terminal electrodes have asimilar or the same shape or that they be arranged in a uniform pattern.The terminal electrodes may vary in shape and position within the array,depending on the particular implementation. Furthermore, it is notnecessary that all of the terminal electrodes be offset or spaced apartfrom the edges of the contact plate or plate substrate. In someexamples, one or more of the electrodes may extend to a respective edgeof the contact plate or plate substrate. Moreover, it is not necessarythat each of the terminal electrodes is electrically coupled to anintegrated circuit or other electrical component. For example, one ormore of the terminal electrodes may be cosmetic in nature or “dummy”terminal electrodes that do not perform an electrical function.

FIGS. 8A-8B depict example cross-sectional views of the example contactplate of FIG. 6. In particular, FIG. 8A depicts an example contact plate802 a that corresponds to the contact plate 602 a, 602 b, 602 c, 602 dof FIGS. 6A-6D. As shown in FIG. 8A, the contact plate 802 a includesterminal electrodes 818 a, 820 a, 828 a that are disposed or positionedon an upper or front surface of the plate substrate 810 a. In thisexample, the plate substrate 810 a may be formed from a non-metallicmaterial including, for example, a polymer or composite material.Example suitable polymer materials for the plate substrate 810 ainclude, but are not limited to, polycarbonate, phenolic, polysulfone,polyethersulfone, polycetal, polyester resins (e.g., polyethylene,polyester, PVC), and other suitable polymers. Example suitable compositematerials for the plate substrate 810 a include, but are not limited to,fiber-reinforced plastics, fiberglass composite, carbon-fibercomposites, laminated composites, and other suitable compositematerials. In some examples, the plate substrate 810 a may be formed, atleast in part, from a metal material including, for example, steel,stainless steel, aluminum, copper, titanium, alloy, or other metalmaterial. The plate substrate 810 a may also be formed from a ceramic,glass, or other similar type of material. In some cases, the platesubstrate 810 a is formed from a metal sheet that has been stamped ormachined from a larger plate or sheet.

If the plate substrate 810 a is formed from a metal or conductivematerial, the terminal electrodes 818 a, 820 a, 828 a may be formedalong the upper or outer surface of the plate substrate 810 a using anelectroplating process. If the plate substrate 810 a is formed from anon-conductive material, then the terminal electrodes 818 a, 820 a, 828a may be formed using a combination of electroless and electroplatingprocesses, as described below.

Whether the plate substrate 810 a is formed from a conductive ornon-conductive material, a pattern of exposed areas that corresponds tothe pattern of the array of terminal electrodes may be formed using aphotoresist masking process. In one example process, a photoresist layeris applied to the upper or outer surface of the plate substrate 810 a. Aphotoresist mask is then positioned over the photoresist layer. Thephotoresist mask may include either a positive pattern or a negativepattern that corresponds to the pattern of the array of terminalelectrodes that is to be formed (see e.g., the pattern of nine terminalelectrodes depicted in FIG. 6). Whether the photoresist mask is apositive pattern or a negative pattern depends on the type ofphotoresist material that is used (positive resist or negative resist),as described below.

The photoresist layer may then be exposed using a light source (e.g., aUV light source or broad spectrum light source). Exposure using thelight source may have different effects on the photoresist layerdepending on the type of photoresist material that is used. In oneexample, if the photoresist is a negative-resist type photoresistmaterial, exposure to the light may cause crosslinking within thephotoresist material making the exposed portions insoluble to aphotoresist developer. In another example, if the photoresist is apositive-resist type photoresist material, exposure to the light maycause uncrosslinking within the photoresist material making the exposedportions soluble to a photoresist developer.

Select areas of the upper surface of the plate substrate 810 a may beexposed by washing or submerging the exposed photoresist material to asolvent, such as a photoresist developer. Portions of the photoresistmaterial that are soluble to the solvent or photoresist developer areremoved and the remaining (insoluble) portions remain to define aplating mask. The pattern of the plating mask may define an array ofplating areas that correspond to the location of the terminal electrodes818 a, 820 a, 828 a.

If the plate substrate 810 a is formed from a conductive material, theterminal electrodes 818 a, 820 a, 828 a may be formed using anelectroplating process. In one example, a first layer of the terminalelectrodes 819 a, 821 a, 829 a may be formed by submerging or immersingthe plate substrate 810 a in a plating solution containing metalcations. An electrical current is then passed through the conductivematerial of the plate substrate 810 a resulting in a thin film of metalbeing formed along the exposed plating areas formed within the platingmask. In the current example, a first solution is used to form a firstconductive layer of the terminal electrodes 819 a, 821 a, 829 a using afirst electroplating process. Then, a second solution having differentmetal cations may be used to form a second or outer conductive layer ofthe terminal electrodes 818 a, 820 a, 828 a. The first or secondconductive layers may include, without limitation, copper, silver,nickel, gold, tin, solder, brass or cadmium. The materials used for thefirst and second layers may be different or they may be the same. Insome cases, only a single layer is formed using a single electroplatingprocess to form the terminal electrodes 818 a, 820 a, 828 a.

If the plate substrate 810 a is formed from a non-conductive material,the terminal electrodes 818 a, 820 a, 828 a may be formed using acombination of electroless and electroplating processes. In one example,a strike or a flash is applied to the plate substrate 810 a to form athin coating. For example, after the plating mask has been formed overthe plate substrate 810 a, the exposed portions of the plate substrate810 a may be immersed or submerged in a cleaning and/or an etchingsolution that increases the micro-roughness of the exposed portions tocreate micro-pores. An example etching solution may include sulfuric orother types of acid solution. After etching, a palladium or othercatalytic solution may be applied to the exposed portions of the platesubstrate 810 a. The palladium or other catalytic solution may result ina thin layer (e.g., approximately 1 μm thick) of conductive materialbeing formed on the exposed portions of the plate substrate 810 a. Insome cases, a 1-5 μm thick layer of palladium is formed along thesurface of the plate substrate 810 a to form the first conductive layerof the terminal electrodes 819 a, 821 a, 829 a.

After the first conductive layer of the terminal electrodes 819 a, 821a, 829 a is formed on the surface of the plate substrate 810 a, one ormore additional layers may be formed over the first layer using anelectroplating process similar to the process described above.Specifically, the plate substrate 810 a and terminal electrodes 819 a,821 a, 829 a are submerged or immersed in a plating solution containingmetal cations. An electrical current is then passed through the terminalelectrodes 819 a, 821 a, 829 a resulting in a thin film of metal beingformed over the terminal electrodes 819 a, 821 a, 829 a. The resultinglayer may define the second conductive layer of the terminal electrodes818 a, 820 a, 828 a. Similar to the previous example, the secondconductive layer may include, without limitation, copper, silver,nickel, gold, tin, solder, brass or cadmium. While only two layers (anelectroless first layer and an electroplated second layer) are shown inthe example of FIG. 8A, more than one electroplated layer may be formedby subjecting the plate substrate 810 a to multiple electroplatingprocesses.

As shown in FIG. 8A, the contact plate 802 a includes a perimeterportion 830 a that at least partially surrounds the terminal electrodes818 a, 820 a, 828 a. This results in the desired offset or position thatis spaced apart or set off from the corresponding edges of the platesubstrate 810 a. However, the presence of the perimeter portion 830 amakes it difficult to couple a current into the first layer of theterminal electrodes 819 a, 821 a, 829 a to perform the electroplatingprocess or processes. This is particularly true if the contact plate 802a is formed from a larger sheet having an array of contact plates thatare treated simultaneously and then cut or separated in order to improvemanufacturing throughput and efficiency. FIGS. 8B, 9A, and 9B depictpotential solutions that may be used to electrically couple to the firstlayer of terminal electrodes 819 a, 821 a, 829 a in order to perform anelectroplating process.

FIG. 8B depicts a cross-sectional view of another example contact plate802 b. The contact plate 802 b may correspond to the contact plate 802 aof FIG. 8A. As shown in FIG. 8B, the contact plate 802 b includesterminal electrodes 818 b, 820 b, 828 b that are disposed or positionedon an upper or front surface of the plate substrate 810 b. In thisexample, the plate substrate 810 b is formed from a non-metallicmaterial including, for example, a polymer or composite material.Example suitable polymer materials for the plate substrate 810 ainclude, but are not limited to, polycarbonate, phenolic, polysulfone,polyethersulfone, polycetal, polyester resins (e.g., polyethylene,polyester, PVC), and other suitable polymers. Example suitable compositematerials for the plate substrate 810 b include, but are not limited to,fiber-reinforced plastics, fiberglass composite, carbon-fibercomposites, laminated composites, and other suitable compositematerials.

As described above with respect to FIG. 8A, the terminal electrodes 818b, 820 b, 828 b may be formed along a non-conductive plate substrate 810b using a combination of electroless and electroplating processes.Initially, a plating mask may be formed over an upper or outer surfaceof the plate substrate 810 b. Similar to the example provided above withrespect to FIG. 8A, a photoresist material may be selectively exposedand then washed to create a plating mask having an array of areas thatcorrespond to a pattern of the array of terminal electrodes 818 b, 820b, 828 b.

Also similar to as described above with respect to FIG. 8A, a firstconductive layer of terminal electrodes 819 b, 821 b, 829 b may beformed by applying a strike or flash to form a thin layer of conductivematerial. In particular, the exposed portions of the plate substrate 810b may be cleaned and etched before being immersed or submerged in apalladium or other catalytic solution. The resulting electroless processmay result in a 1-5 μm thick layer of palladium that is formed along thesurface of the plate substrate 810 b to form the first conductive layerof the terminal electrodes 819 b, 821 b, 829 b.

After performing the electroless plating process, one or more subsequentelectroplating processes may be used to form the terminal electrodes 818b, 820 b, 828 b. As discussed above, the presence of the perimeterportion 830 b may make it difficult to couple a current into each of thefirst conductive layer of terminal electrodes 819 b, 821 b, 829 b toperform an electroplating process. As discussed above, the desiredperimeter portion 830 b results in the terminal electrodes 818 b, 820 b,828 b being offset or set back from the respective edges of the platesubstrate 810 b.

To help solve the problem of passing a current through the firstconductive layer of terminal electrodes 819 b, 821 b, 829 b, theconfiguration depicted in FIG. 8B includes a rear conductive layer 831 bformed along a rear, lower, or inner surface of the plate substrate 810b. The rear conductive layer 831 b may be formed from a conductivematerial including, without limitation, copper, silver, nickel, gold,tin, solder, brass, conductive carbon, or cadmium. As shown in FIG. 8B,each of the first conductive layer of terminal electrodes 819 b, 821 b,829 b is electrically coupled to the rear conductive layer 831 b by acorresponding via, 822 b, 824 b, 826 b, that extend through the platesubstrate 810 b. The vias 822 b, 824 b, 826 b may be formed by drillingholes through the plate substrate 810 b and then filling the holes witha conductive material. In some cases, the vias 822 b, 824 b, 826 b areformed when forming the rear conductive layer 831 b. The vias 822 b, 824b, 826 b and the rear conductive layer 831 b may be formed from the sameconductive material.

Using the configuration depicted in FIG. 8B, an electrical current maybe applied to the rear conductive layer 831 b, which is passed to eachof the terminal electrodes 818 b, 820 b, 828 b by a corresponding via822 b, 824 b, 826 b. Thus, one or more subsequent electroplatingprocesses can be used to form the terminal electrodes 818 b, 820 b, 828b by applying the current to a single element, the rear conductive layer831 b. In some cases, the rear conductive layer 831 b is part of alarger conductive layer formed along the lower or inner surface of alarger sheet. The larger sheet may have an array of contact plates thatare treated simultaneously and then cut or separated in order to improvemanufacturing throughput and efficiency.

FIGS. 9A-9B depict example connecting structures for a contact plate.FIGS. 9A and 9B depict additional options for coupling electricalcurrent into a conductive layer of a first conductive layer of aterminal electrode 918 a in order to perform an electroplating process.As shown in FIG. 9A, a lower or first conductive layer of a terminalelectrode 918 a may be formed over a surface of a plate substrate. Theterminal electrode 918 a may correspond to a lower or first layer of aterminal electrode similar to terminal electrode 618 of FIG. 6. In theexample of FIG. 9A, the terminal electrode 918 a is coupled to aconductive periphery portion 930 a by a bridge portion 950 a. In thisexample, the periphery portion 930 a is formed from a conductivematerial or conductive layer that extends all the way to the edge of theplate substrate, which may facilitate an electrical connection to acurrent source during electroplating. By applying a current to theconductive periphery portion 930 a, the electrical current may be passedto the terminal electrode 918 a via the bridge portion 950 a during anelectroplating process.

After performing one or more electroplating processes to form the outeror upper layer of the terminal electrode 918 a, the bridge portion 950 amay be removed to electrically isolate the terminal electrode 918 a fromother conductive portions of the card, including the conductiveperiphery portion 930 a. The bridge portion 950 a may be removed by, forexample, laser ablating the bridge portion 950 a using an ablating laserhaving a spot size that is less than the width of the bridge portion 950a. In some cases, after the bridge portion 950 a is removed, alaser-ablated or ablated region 952 a is formed, that is over thesubstantially same area as the bridge portion 950 a and may expose the(non-conductive) material of the plate substrate. The ablated region 952a may be substantially free of conductive material and may electricallyisolate the terminal electrode 918 a from the conductive peripheryportion 930 a. In some cases. the ablated region 952 a may extendpartially into the plate substrate. The bridge portion 950 a may also beremoved using a mechanical cutter, etching solution, or other materialremoval technique to define a machined region that corresponds to theablated region 952 a indicated on FIG. 9A. In some cases, the conductiveperiphery portion 930 a is also removed after the outer or upper layerof the terminal electrode 918 a is formed using an electroplatingprocess.

FIG. 9B depicts another example configuration for coupling electricalcurrent into a conductive layer of a first layer of a terminal electrode918 b in order to perform an electroplating process. As shown in FIG.9B, a lower or first layer of a terminal electrode 918 b may be formedover a surface of a plate substrate. The terminal electrode 918 b maycorrespond to a lower or first layer of a terminal electrode similar toterminal electrode 618 of FIG. 6. In the example of FIG. 9B, theterminal electrode 918 b is coupled to a bridge portion 950 b that isformed from a conductive material or conductive layer that extends allthe way to the edge of the plate substrate. Similar to the other exampleprovided above, the bridge portion 950 b may facilitate an electricalconnection to a current source during electroplating. By applying acurrent to the bridge portion 950 b, an electrical current may be passedto the terminal electrode 918 b during an electroplating process.

After performing one or more electroplating processes to form the outeror upper layer of the terminal electrode 918 b, the bridge portion 950 bmay be removed to create an offset or gap between the terminal electrode918 b and the corresponding edge of the plate substrate. As shown inFIG. 9B, the contact plate includes a non-conductive periphery portion930 b that separates the terminal electrode 918 b from the edges of theplate substrate. Similar to the previous example, the bridge portion 950b may be removed by, for example, laser ablating the bridge portion 950b using an ablating laser having a spot size that is less than the widthof the bridge portion 950 b. In some cases, after the bridge portion 950b is removed, a laser-ablated or ablated region 952 b is formed that isover the substantially same area as the bridge portion 950 b and mayexpose the (non-conductive) material of the plate substrate. The ablatedregion 952 b may be substantially free of conductive material and mayelectrically isolate the terminal electrode 918 b from a conductiveportion of the contact plate along the upper surface (if any exists). Insome cases, the ablated region 952 b may extend partially into the platesubstrate. The bridge portion 950 b may also be removed using amechanical cutter, etching solution or other material removal techniqueto define a machined region that corresponds to the ablated region 952 bindicated on FIG. 9B.

FIG. 10 depicts an example marking on an electronic card. In particular,FIG. 10 depicts a marking 1020 that includes a first laser-formed relieffeature 1022 and a second laser-formed relief feature 1024 formed intothe front surface 1010 of the electronic card 1000. As described in moredetail below with respect to FIGS. 11A-15B, the laser-formed relieffeatures 1022, 1024 (“relief features”) may extend through a coatinglayer of the electronic card 1000 and, in some instances, may extend atleast partially into the card substrate.

The marking 1020 may include one or more printed portions in addition tothe relief features 1022, 1024. The printed portions may be formed byapplying an ink, dye, or pigment to the front surface 1010 of theelectronic card 1000. The marking 1020 may include a symbol like thelogo depicted in FIG. 10. The marking 1020 may also include text ornumerical information including, for example, a serial number, accountnumber, user name, institution name, telephone numbers, addresses, andother text, numerical, or symbolic information.

FIGS. 11A-11E depict examples of cross-sectional views of examplemarkings. The example markings depicted in FIGS. 11A-11E may correspondto one or more of the markings described above including, for examplemarking 1020 of FIG. 10 and markings 114 of FIG. 1A.

FIG. 11A depicts an example marking 1140 a formed along an exteriorsurface of a coating layer 1134 a. In this example, the substrate 1102 ais coated or at least partially covered on both sides by coating layers1132 a and 1134 a. The coating layers 1132 a and 1134 c may be formed inaccordance with other coating layers described herein, a redundantdescription of which is omitted for clarity. In the example of FIG. 11A,the marking 1140 a includes a marking material that is deposited orotherwise disposed along the upper or exterior surface of the coatinglayer 1134 a. The marking 1140 a may include a printed ink, paint, orother material that is visually distinct from the surrounding portionsof the coating layer 1134 a. While marking 1140 a is depicted in FIG.11A as being exposed, the marking 1140 a may be coated or at leastpartially covered by a protective film or coating, which may betranslucent or transparent to allow visibility of the marking 1140 a.

FIG. 11B depicts an example marking 1140 b formed below an exteriorsurface of a coating layer 1134 b. As shown in FIG. 11B, the marking1140 b may be a subsurface marking that is formed below the exteriorsurface of the coating layer 1134 b but above a surface of the substrate1102 b. The marking 1140 b may be formed using a laser beam that isfocused into a subsurface region of the coating layer 1134 b. Themarking 1140 b may be visible or viewable from the exterior surface butalso substantially indelible or protected from wear or abrasion. Themarking 1140 b may also be applied after the electronic card has beenformed and may include personalized information including, for example,an account number, account holder's name, account type, card issuerinformation, expiration date, CVC code, or other card-specificinformation.

In some instances, the coating layer 1134 b is formed from multiplelayers, similar to other embodiments described herein. In particular,the coating layer 1134 b may include a first layer 1136 b disposed overa surface of the substrate 1102 b and that may include a primer and acolor layer. The color layer and/or primer layer may include a pigmentdispersed throughout a polymer or other type of binder similar to theother embodiment described herein. The coating layer 1134 b may alsoinclude a second layer 1138 b that is disposed over the first layer 1136b. The second layer 1138 b may include a transparent or translucentmaterial that has a hardness that is greater than the first layer 1136b. Similar to other examples described herein, the second layer 1138 bmay include an acrylate material, UV-curable polymer, DLC, or othersimilar type of coating. The coating layer 1132 b may be formed of asimilar or the same multi-layer construction as coating layer 1134 b.Similar to previous examples, the coating layers 1132 b, 1134 b may be asingle continuous layer or may be a discontinuous layer having a breakalong an edge or edges of the electronic card.

As shown in FIG. 11B, the marking 1140 b may be formed below the secondlayer 1138 b and at least partially into the first layer 1136 b. In oneexample, the marking 1140 b is formed by focusing a laser through thesecond layer 1138 b and into the first layer 1136 b to chemically and/orphysically alter a region of the first layer 1136 b. In some instances,the second layer 1138 b is substantially unaltered or intact afterforming the marking in the first layer 1136 b. In some instances, thesecond layer 1138 b has been affected, but only in an internal regionand the exterior surface of the second layer 1138 b remainssubstantially intact. By way of example, a UV laser having a wavelengthbetween 10 and 400 nm having a power of less than 1 watt is used to formthe marking 1140 b. In some cases, a UV laser having a wavelengthbetween 300 and 377 nm and a power of less than 0.5 watts is used toform the marking 1140. The UV laser may have a pulse width that rangesbetween 0.5 nanosecond to 40 nanoseconds. The UV laser may also have afrequency of approximately 225 kHz to 400 kHz.

With regard to FIG. 11B, in some embodiments, a laser may be used toform a dark or darkened region along the first layer 1136 b by creatinga series of laser-treated spots. Each spot may be created using a UVlaser to disperse, ablate, or otherwise alter the pigment (e.g., atitanium oxide pigment) to alter the reflective light properties of thefirst layer 1136 b. In some cases, the laser at least partially oxidizesthe treated portion of the first layer 1136 b. The laser-treated spotsmay have a diameter that ranges between 5 um and 60 um and are arrangedin a pattern of approximately 5000 dots per inch to approximately 8000dots per inch. In some cases, the spot density is approximately 6500dots per inch to approximately 7500 dots per inch. In some cases, thepitch or spacing of the spots is different in different directions. Forexample, the pitch of the spots may be approximately 0.5 to 1.5 um in afirst direction and approximately 5 um to 10 um in a second directionthat is perpendicular to the first direction. The spots may be formedusing back-and-forth multi-directional passes to define a “serpentine”or dual-direction raster laser treatment pattern or a series of singledirection passes to define a “typewriter” or single-direction rasterlaser treatment pattern. In some cases, multiple passes of the laser aremade over a given region to form the laser marking 1140 b. In somecases, the laser marking 1140 b has a feature size (e.g., a line width)that is determined by the spot side of the laser (e.g., between 5 um and60 um). In some cases, the laser marking 1140 b includes larger areafeatures that are formed using an array of laser-treated spots whileappearing substantially uniform to the naked eye when viewed fromseveral inches away.

FIG. 11C depicts an example marking 1140 c that is etched into the coverlayer 1134 c. In this example, the marking 1140 c is formed by removinga portion of the cover layer 1134 c to expose a portion of the substrate1102 c. The substrate 1102 c may have a different color or visualappearance that may be visually distinct from the surrounding portionsof the cover layer 1134 c to provide the visual qualities of the marking1140 c. In some cases, the surface of the substrate 1102 c is treated toprovide a color that enhances the visual distinction or appearance ofthe marking 1140 c. As described in more detail with respect to FIGS.12-14, an exposed portion of a substrate may be polished and/or enhancedwith an oxide coating to provide a marking that may be visuallydistinct.

In the example of FIG. 11C, the marking 1140 c may be formed by removinga portion of the cover layer 1134 c. In some cases, the cover layer 1134c may be exposed to a laser, which ablates or otherwise removes portionsof the cover layer 1134 c to expose the underlying substrate 1102 c. Inother cases, the respective portions of the cover layer 1134 c may beremoved using a chemical etching process, a mechanical etching process,or other material removal technique.

FIG. 11D depicts an example marking 1140 d that is etched partially intothe cover layer 1134 d. As shown in FIG. 11D, the marking 1140 d definesor is defined by a recess or groove that is formed into the cover layer1134 d but does not expose portions of the underlying substrate 1102 d.In some implementations, the cover layer 1134 d is formed from multiplelayers, two or more of which have a different color or visualappearance. One or more top or outer layers may be removed to expose alower or inner layer having a different color or visual appearance fromthe top or outer layers thereby forming a marking 1140 d having adistinct visual appearance.

In the example of FIG. 11D, the marking 1140 d may be formed by removinga portion of the cover layer 1134 d. In some cases, the cover layer 1134d may be exposed to a laser, which ablates or otherwise removes portionsof the cover layer 1134 d to expose a lower or inner sublayer of thecover layer 1134 d having a different color or distinct visualappearance. In other cases, the respective portions of the cover layer1134 d may be removed using a chemical etching process, a mechanicaletching process, or other material removal technique.

FIG. 11E depicts an example marking 1140 e that is etched into the coverlayer 1134 e and a portion of the underlying substrate 1102 e. As shownin FIG. 11E, the marking 1140 e defines or is defined by a recess orgroove that is formed into the cover layer 1134 e and an outer or upperportion of the substrate 1102 e. In the example of FIG. 11E, the recessor groove has a beveled or angled cross section. In particular, therecess of the marking 1140 e includes two opposing angled sidewalls,which may provide the desired visual effect. The substrate 1102 e mayhave a color or visual appearance that is visually distinct from thesurrounding portions of the cover layer 1134 e to provide the visualqualities of the marking 1140 e. In some cases, the exposed portions ofthe substrate 1102 e are treated to provide a color that enhances thevisual distinction or appearance of the marking 1140 e. As described inmore detail with respect to FIGS. 12-14, an exposed portion of asubstrate may be polished and/or enhanced with an oxide coating toprovide a visually distinct marking.

In the example of FIG. 11E, the marking 1140 e may be formed by removinga portion of the cover layer 1134 e and substrate 1102 e. In some cases,the cover layer 1134 e and the substrate 1102 e may be exposed to alaser, which ablates or otherwise removes portions of the cover layer1134 e and substrate 1102 e to form a groove or recess. In other cases,the respective portions of the cover layer 1134 e and the substrate 1102e may be removed using a chemical etching process, a mechanical etchingprocess, or other material removal technique.

FIG. 11F depicts an example marking 1140 f that is etched into the coverlayer 1134 f and a portion of the underlying substrate 1102 f. As shownin FIG. 11F, the marking 1140 f defines or is defined by a recess orgroove that is formed into the cover layer 1134 f and an outer portionof the substrate 1102 f. In the example of FIG. 11F, the recess orgroove has a rectangular cross section. The recess of the marking 1140 fhas a substantially flat bottom surface, which may provide the desiredvisual effect. Similar to previous examples, the substrate 1102 f mayhave a different color or visual appearance that may be visuallydistinct or visually different from the surrounding portions of thecover layer 1134 f to provide the visual qualities of the marking 1140f. Similar to other examples, one or more exposed surfaces of thesubstrate 1102 f may be treated to provide a color that enhances thevisual distinction or appearance of the marking 1140 f. As described inmore detail with respect to FIGS. 12-14, an exposed portion of asubstrate may be polished and/or enhanced with an oxide coating toprovide a marking that may be visually distinct.

In the example of FIG. 11F, the marking 1140 f may be formed by removinga portion of the cover layer 1134 f and substrate 1102 f. In some cases,the cover layer 1134 f and the substrate 1102 f may be exposed to alaser, which ablates or otherwise removes portions of the cover layer1134 f and substrate 1102 f to form a groove or recess. In other cases,the respective portions of the cover layer 1134 f and the substrate 1102f may be removed using a chemical etching process, a mechanical etchingprocess, or other material removal technique.

FIGS. 12-14 depict cross-sectional views of an example marking formedinto the surface of an electronic card. In particular, FIG. 12 depicts across-sectional view of a relief feature 1222. The relief feature 1222of FIG. 12 may correspond to the first laser-formed relief feature 1022of FIG. 10. FIG. 12 provides an example of a fine or precision markingwhich can be produced using a laser-based technique. In the example ofFIG. 12, a laser may be used to remove a portion of the coating layer1230 and expose a portion of the substrate 1202, which may be formedfrom a metal material. As shown, removal of a portion of the coatinglayer 1230 may not significantly distort an adjacent portion of thecoating layer 1230 or the underlying substrate 1202. While the exposedsubstrate 1202 is depicted as having an angled non-planar feature, insome implementations the exposed substrate 1202 may be substantiallyflat or planar. Further, a metal oxide layer may be formed on theexposed metal substrate 1202 as described below with respect to FIG. 14.

As shown in FIG. 12, the relief feature 1222 includes a pair of recesswalls 1264 that define a recess extending through the coating layer1230. The relief feature 1222 also includes a recessed marking feature1266 that defines a bottom of the recess. The recessed marking feature1266 may have a coating, texture, coloring, or appearance that causesthe recessed marking feature 1266 to be visually distinct from anadjacent portion of the coating layer 1230. The recess defined by thepair of recess walls 1264 and the marking feature 1266 has a width W,which may be determined, in part, by a spot size diameter of a laserused to form the relief feature 1222. Note that while the pair of recesswalls 1264 are depicted as forming an angle of approximately 90° withrespect to the front surface 1210, the embodiments are not limited tothis particular geometry. In other embodiments, one or both of the pairof recess walls 1264 may be formed at a (non-perpendicular) angle withrespect to the front surface 1210.

As shown in FIG. 12, the coating layer 1230 is formed along the surface1212 of substrate 1202 and the recessed marking feature 1266 is formedinto the surface 1212 of the substrate 1202 to define marking surface1214. The marking surface 1214 may be at the same height as the surface1212 or, as shown in FIG. 12, may be at a different height as thesurface 1212. In some embodiments, the marking surface 1214 is recessedby 5 μm or less, 3 μm or less, 2 μm or less, or 1 μm or less, withrespect to the surface 1212.

In general, the marking surface 1214 may have a texture which gives therecessed marking feature 1266 a visual appearance that may be differentor visually distinct from an adjacent portion of the coating layer 1230.For example, marking surface 1214 may have a surface finish with aroughness corresponding to that of a polished surface. The roughness ofmarking surface 1214 may be from about 1 μm to about 5 μm. In anadditional example, the roughness of marking surface 1214 may be greaterthan 5 μm, or greater than 10 μm. One measure of surface roughness isthe parameter R_(a) which is a measure of the amplitude of the roughnessprofile (arithmetic average value of roughness determined fromdeviations about a center line). Another parameter is S_(m), which isthe mean spacing between peaks in the roughness profile. Reflectance mayalso be used as a measure of surface roughness.

In some implementations, the marking surface 1214 may include a dye,ink, or other marking element that may be used to provide a markingcolor for the recessed marking feature 1266. In some cases, the markingsurface 1214 includes an oxide layer which may provide a marking colorfor the recessed marking feature 1266. The metal oxide may be athermally grown metal oxide and may be thermally grown on a metalmaterial by heating the substrate using a laser. Examples of an oxidelayer formed within a relief feature are described below with respect toFIG. 14.

As shown in FIG. 12, the coating layer 1230 may be a multilayer coating.In the current example, the coating layer 1230 includes a first layer1234 having a thickness T₁ and a second layer 1236 having a thicknessT₂. The thickness of the first layer 1234 may be greater than that ofthe second layer 1236. In some embodiments, the combined thickness ofthe coating layers is from 50 μm to 500 μm or from 100 μm to 300 μm. Thefirst layer 1234 is disposed over exterior surface 1212 of the substrate1202 and, as shown in FIG. 12, may contact the surface 1212 along aninterface between coating layer 1230 and the substrate 1202. The secondlayer 1236 is disposed over the first layer 1234.

The first layer 1234 may include one or more polymer materials. In oneexample, the first layer 1234 includes a first urethane layer (e.g., aprimer layer) that is adhered to a surface of the substrate 1202. Thefirst layer 1234 may include one or more additional urethane materialsthat are bonded or adhered to the substrate 1202 via the first urethanelayer or primer layer. The one or more additional urethane materials mayinclude a dual urethane or polyurethane formulation that is applied tothe first urethane layer or primer layer.

In some embodiments, the first layer 1234 includes pigment particlesdispersed within a polymer binder. As an example, the pigment particlesmay be inorganic pigment particles that include a metal oxide including,without limitation, titanium oxides (TiO₂, Ti₂O₃), zinc oxides (ZnO),manganese dioxides (MnO₂), and iron oxides (Fe₃O₄). The particles mayhave a size range of 0.1 μm to 10 μm or 0.1 μm to 1 μm. The first layer1234 may further comprise other additives or constituent components.

In some embodiments, the second layer 1236 is transparent and may beformed from a transparent polymer. The transparent polymer of the secondlayer 1236 may have a hardness and/or an abrasion resistance greaterthan that of the first layer 1234. For example, the second layer 1236may comprise an acrylate polymer (e.g., acrylic) or an epoxy polymer. Insome cases, the coating layer 1236 includes a UV-curable polymer. Insome cases, the second layer 1236 includes a diamond-like carbon (DLC)coating or other hard material that may be formed in a thin layer. Thesecond layer 1236 may also comprise filler materials, including, forexample, nanoscale inorganic or diamond materials. Nanoscale fillermaterials may have a diameter less than 100 nm or less than 50 nm.

The first layer 1234 and/or second layer 1236 may be deposited on thesubstrate 1202 using a deposition or layer application processincluding, for example, physical vapor deposition (PVD), atomicdeposition coating (ALD), spray coating, dip coating, and other similarmaterial deposition processes. In some cases, the first layer 1234 isapplied to a primer layer that is formed on a surface of the substrate1202. The foregoing discussion of the first and second layers 1234, 1236is not limited to the example of FIG. 12, but applies more generally tomultilayer coatings that are described with respect to other aspects ofthe present disclosure.

In the example of FIG. 12, the relief feature 1222 includes a recessedmarking feature 1266 having a geometric feature 1272 that extends intothe substrate 1202. As shown in FIG. 12, the geometric feature 1272 is achannel formed into the substrate 1202 and having an angular or v-shapedcross-sectional shape that may generally be referred to as a “channel”1272. The channel 1272 may have a width about equal to the width W ofthe recessed marking feature 1266. In some cases, a width of the channel1272 may be from about 80% to 100% of the width of the recessed markingfeature 1266. The channel 1272 may have an angle θ that may be greaterthan about 45 degrees and less than 180 degrees or from about 60 degreesto about 120 degrees.

FIG. 13 depicts a cross-sectional view of another example laser-formedrelief feature 1322. Relief feature 1322 of FIG. 13 may correspond tothe relief feature 1022 of FIG. 10. As shown in FIG. 13, the relieffeature 1322 includes a pair of recess walls 1364 that extend into thecoating layer 1330 to at least partially define a recess. In thisexample, the pair of recess walls 1364 extend at a non-perpendicularangle with respect to the front surface 1310 of the electronic card. Asshown in FIG. 13, the relief feature 1322 also includes a recessedmarking feature 1366 that defines a bottom of the recess. In thisexample the recessed marking feature 1366 includes a geometric feature1372 having a curved or contoured shape that extends into the substrate1302 a depth D and having a width W. The geometric feature 1372 may bedescribed as a channel having angled walls that extend from a roundedbottom or trough. The geometric feature 1372 may have an angle θ thatmay be greater than about 45 degrees and less than 180 degrees or fromabout 60 degrees to about 120 degrees. In some cases, the angled wallsof the geometric feature 1372 correspond to the angle of the recesswalls 1364.

FIG. 14 depicts another example laser-formed relief feature. Thelaser-formed relief feature 1422 may correspond to the relief feature1022 described above with respect to FIG. 10. Similar to the examplesdescribed above, the relief feature 1422 is formed along an exteriorsurface 1410 and extends into the coating layer 1430 and at leastpartially into an underlying metal substrate 1402, which may be formedfrom a metal material. In this example, the relief feature 1422 includesa marking surface 1414 having one or more oxide layers that provide adifferent color, distinct color, or particular visual appearance for therelief features. Specifically, the relief feature 1422 includes a firstoxide layer 1452 having a first thickness T₁ and a second oxide layer1454 having a second thickness T₂ that is greater than the firstthickness T₁.

The metal oxide layers 1452, 1454 may include a thermally grown metaloxide. For example, the metal oxide layers 1452, 1454 may be thermallygrown on the marking surface 1414 of the metal substrate 1402 by heatingthe substrate 1402 using a laser or other focused heat or energy source.Suitable metal materials include, but are not limited to, titaniumalloys, steels, or zirconium-based, titanium-based, or iron-based bulksolidifying alloy substrates. In some embodiments, the thermally grownmetal oxide may have a porosity less than that of an anodically grownporous metal oxide. In embodiments, the metal oxide may comprise atitanium oxide, an iron oxide, a chromium oxide, a zirconium oxide orcombinations thereof.

The thickness of a metal oxide layer can affect the color of the relieffeature 1422 in several ways. For example, the metal oxide layers 1452,1454 may display a color as a result of interference of light reflectedfrom the metal oxide and the underlying metal substrate 1402. Typically,the interference color displayed depends upon the thickness of the metaloxide. A metal oxide having a thickness too great to displayinterference colors may appear dark. When the metal oxide is very thin(or is not present), the recessed marking feature may appear bright ormetallic. A variety of colors may be obtained, including, but notlimited to, blue, purple, pink, orange, yellow, gold, brown, and green.Suitable thicknesses of the metal oxide layer to achieve a color fromlight interference may depend on the composition and crystallinity ofthe metal oxide layer as well as the desired color to be achieved. As anexample, a thickness of the metal oxide layer may be from 50 nm to 500nm to obtain a color through interference of light.

As shown in FIG. 14, the first oxide layer 1452 has a first thicknessT₁, which may result in a first color or appearance and the second oxidelayer 1454 has a second thickness T₂ that is greater than the firstthickness T₁ and may result in a second color or appearance that isdifferent than the first color or appearance. The configuration of FIG.14 may produce different visual effects. In some implementations, therelief feature 1422 of FIG. 14 may appear to have the first color orvisual appearance when viewed from one angle and may appear to have thesecond color or visual appearance when viewed from another, differentangle. In some implementations, the first color of the first oxide layer1452 and the second color of the second oxide layer 1454 are combined toprovide an apparent third color when viewed by the naked (unaided) eyeat a normal or typical viewing distance.

FIGS. 15A-15B depict other example laser-formed relief features.Specifically, FIG. 15A depicts an enlarged view of a relief feature1524, which may correspond to relief feature 1024 of FIG. 10. FIG. 15Bdepicts a cross-sectional view of the relief feature 1524 along sectionF-F of FIG. 15A. The relief feature 1524 is provided as an example ofhow a relief feature 1524 may be formed over an area or region of theexterior surface of the electronic card. In general, the relief feature1524 may be visually and tactilely distinct from surrounding or adjacentportions of the surface of the electronic card.

As shown in FIG. 15B, relief feature 1524 extends into the coating layer1530 and at least partially into the substrate 1502, which may be formedfrom a metal material. The relief feature 1524 includes a recess wall1564 that defines at least a portion of a recess. The relief feature1524 also includes a first recessed marking feature 1566 that is formedaround the periphery of the relief feature 1524. The first recessedmarking feature 1566 may include a geometric feature, which, in thisexample, is a channel 1550 having a rounded or contoured shape andextending into the substrate 1502. The relief feature 1524 also includesa second recessed marking feature 1568 that is at least partiallysurrounded by the first recessed marking feature 1566.

The second recessed marking feature 1568 may cover a majority of thearea of the relief feature 1524 and may provide the main appearance orvisual characteristics of the relief feature. In this example, thesecond recessed marking feature 1568 includes a surface texture 1552,which may provide a distinct visual appearance as compared tosurrounding or adjacent portions of the electronic card. In someimplementations, the second recessed marking feature 1568 may alsoinclude one or more oxide layers that provide one or more colors for therelief feature 1524.

FIGS. 16A-16C depict example chamfers of an electronic card. Theelectronic cards 1600 a, 1600 b, 1600 c, of FIGS. 16A, 16B, and 16C maycorrespond to or be similar to the electronic card 100 described abovewith respect to other figures. As described previously, chamfers mayprovide various functional and/or visual benefits for an electroniccard. For example, chamfered edges or chamfers may facilitate insertionof the card into a card reader or card-reading device. The chamferededges or chamfers may also provide a desired tactile feel or make theelectronic card easier to handle. Additionally, the chamfered edges orchamfers may provide a distinct visual appearance.

FIG. 16A depicts a cross-sectional view of chamfered edges 1610 a, 1612a of the electronic card 1600 a having exposed portions (chamferportions) of a card substrate 1602. Similar to other embodimentsdescribed herein, the electronic card 1600 a includes a substrate 1602that may be formed from a metal or metallic material. The electroniccard 1600 a also includes a coating layer 1630 that may include multiplelayers. As shown in FIG. 16A, the coating layer 1630 includes a firstlayer 1632, which may be used to provide a color or appearance for theelectronic card 1600 a. As described previously, the first layer 1632may include a pigment or dye that is dispersed within a polymer orpolymer binder. The coating layer 1630 also includes a second layer 1634that may be formed from a hard and/or transparent material and ispositioned over the first layer 1632. As described previously, thesecond layer 1634 may include a transparent polymer including, forexample, an acrylic (e.g., acrylate polymer) or an epoxy (e.g., epoxypolymer). In some cases, the coating layer 1632 includes a UV-curablepolymer. In some cases, the second layer 1634 includes a hard coating,such as a diamond-like carbon (DLC) coating.

As shown in FIG. 16A, the electronic card 1600 a includes frontchamfered edge 1610 a and rear chamfered edge 1612 a. The frontchamfered edge 1610 a may extend around or surround the front surface ofthe electronic card 1600 a and the rear chamfered edge 1612 a may extendaround or surround the rear surface of the electronic card 1600 a. Inthis example, the chamfered edges 1610 a, 1612 a include an exposedportion of the substrate 1602, also referred to herein as a chamferportion of the substrate 1602. In some cases, the exposed or chamferportion of the substrate 1602 is polished or is otherwise treated toprovide a smooth surface finish. In some cases, the exposed or chamferportions are brushed or etched to provide a textured surface finish.

The chamfer portion of the substrate 1602 partially defining thechamfered edges 1610 a, 1612 a may have a visual appearance that isdistinct from non-chamfered portions of the electronic card 1600 a. Insome implementations, the exposed or chamfer portions of the substrate1602 along the chamfered edges 1610 a, 1612 a may have the natural colorof the metal material that forms the substrate 1602. In otherimplementations, the exposed or chamfer portions of the substrate 1602along the chamfered edges 1610 a, 1612 a may be anodized or oxidized toform an anodized or oxidized layer. The anodized or oxidized layer mayhave a natural color or may include a dye or pigment to provide adesired appearance or color.

As shown in FIG. 16A, the electronic card 1600 a also defines a sidewallor substrate edge that extends between the front chamfered edge 1610 aand the rear chamfered edge 1612 a. In the embodiment depicted in FIG.16A, the sidewall or substrate edge is coated with the same or similarcoating layer 1630 as on the front and rear surfaces of the electroniccard 1600 a.

FIG. 16B depicts another example electronic card 1600 b having chamferededges 1610 b, 1612 b with exposed or chamfer portions of the substrate1602 that are coated with oxide layers 1640, 1642. Similar to asdescribed above with respect to FIG. 14, the oxide layers 1640, 1642 maybe thermally grown oxides that are formed to a specific thickness inorder to provide the desired color or appearance.

For example, the oxide layers 1640, 1642 may display a color as a resultof interference of light reflected from the metal oxide and theunderlying metal substrate 1602. As described previously, a metal oxidehaving a thickness too great to display interference colors may appeardark. When the metal oxide is very thin (or is not present), therecessed marking feature may appear bright or metallic. A variety ofcolors may be obtained, including, but not limited to, blue, purple,pink, orange, yellow, gold, brown, and green. Suitable thicknesses ofthe oxide layers 1640, 1642 to achieve a color from light interferencemay depend on the composition and crystallinity of the layer as well asthe desired color to be achieved. As an example, a thickness of theoxide layers 1640, 1642 may be from 50 nm to 500 nm to obtain a colorthrough interference of light. In some implementations, the substrate1602 is both anodized and coated with the oxide layers 1640, 1642 toprovide a particular color or visual effect.

Similar to the other examples described above, the electronic card 1600b of FIG. 16B may include a coating layer 1630 that provides a visualappearance or color for the electronic card 1600 b. Similar to theprevious examples, the coating layer 1630 may include multiple layersincluding sublayers 1632 and 1634. The appearance of the coating layer1630 may be distinct from and/or may contrast with the color orappearance of the chamfers 1610 b, 1612 b having oxide layers 1640,1642. As shown in FIG. 16B, the electronic card 1600 a also defines asidewall or substrate edge that extends between the front chamfered edge1610 a and the rear chamfered edge 1612 a. In the embodiment depicted inFIG. 16A, the sidewall or substrate edge is coated with the same orsimilar coating layers 1630 as on the front and rear surfaces of theelectronic card 1600 a.

FIG. 16C depicts another example electronic card 1600 c having chamferededges 1610 c, 1612 c with exposed or chamfer portions of the substrate1602. In the example of FIG. 16C, the substrate 1602 also defines anexposed sidewall or substrate edge 1650. In some cases, the exposedsidewall or substrate edge 1650 is coated with a thin and/or transparentcoating that protects the substrate 1602 but allows the natural color ofthe substrate 1602 to be visible along the edge of the electronic card1600 c. Similar to the other examples described above, the electroniccard 1600 c may include a coating layer 1630 that provides a visualappearance or color for the electronic card 1600 c. Similar to theprevious examples, the coating layer 1630 may include multiple layersincluding sublayers 1632 and 1634. The appearance of the coating layer1630 may be distinct from and/or may contrast with the color orappearance of the chamfers 1610 c, 1612 c, and/or the exposed sidewall1650.

FIG. 17 depicts example components of an electronic card 1700. Theelectronic card 1700 may correspond to any one of the electronic cardembodiments described herein. Specifically, the electronic cardsdescribed herein may include one or more components described below withrespect to electronic card 1700. However, the schematic diagram of FIG.17 is not intended to be an exhaustive or comprehensive description ofthe components or elements of an electronic card. Further, one or moreof the components or elements described below may be optional or omittedfrom any particular implementation.

In accordance with some embodiments, the electronic card 1700 may befoldable or bendable. For example, the electronic card 1700 may defineone or more foldable regions or bendable regions that are configured tofold or flex repeatedly during use. The various components describedherein may be adapted to facilitate a foldable card including, forexample, flexible electronic components, flexible battery elements,flexible display elements, and the like.

As shown in FIG. 17, the electronic card 1700 includes one or moreprocessing unit(s) 1702. The processing unit(s) 1702 may include one ormore computer processors or microcontrollers that are configured toperform various operations or functions. In some cases the processingunit(s) 1702 perform the various operations in response tocomputer-readable instructions or firmware. The processing unit(s) 1702may include a central processing unit (CPU), numerical processing unit(NPU), and other processing circuitry. The processing unit(s) 1702 mayinclude other processors within the electronic card 1700 includingapplication specific integrated chips (ASIC) and other microcontrollerdevices.

In addition, the processing unit(s) 1702 may be operatively connected tomemory 1704. The processing unit(s) 1702 may be operatively connected tothe memory 1704 via an electronic bus or bridge. In some cases, theprocessing unit(s) 1702 may be directly coupled to the memory 1704. Thememory 1704 may include a variety of types of non-transitorycomputer-readable storage media, including, for example, read accessmemory (RAM), read-only memory (ROM), erasable programmable memory(e.g., EPROM and EEPROM), or flash memory. The memory 1704 is configuredto store computer-readable instructions, encoded security keys, securitycodes, serial numbers, identifying information, financial information,medical information, or other types of data or records.

As shown in FIG. 17, the electronic card 1700 may also include wirelesscircuitry 1706. As discussed previously, the electronic card 1700 mayinclude a wireless transceiver or other wireless electronics that areconfigured to interface with an external device using a wirelesscommunication protocol. In some implementations, if the electronic card1700 interfaces with external devices using primarily the wirelesscircuitry 1706, the electronic card 1700 may be referred to as acontactless card. It is not necessary that a contactless card notinclude physical contacts or terminals. Additionally, if the electroniccard 1700 is a contact card, the electronic card 1700 may not includewireless circuitry.

The electronic card 1700 may include a coded magnetic component 1708. Asdescribed above with respect to some embodiments, the electronic card1700 may include a magnetic element (e.g., a ferromagnetic film) thatdefines a magnetic region or area along a surface of the electronic card1700. The coded magnetic component 1708 may store encoded information ordata and allow the information or data to be read using an external cardreader or card-reading device. The coded magnetic component 1708 may beconfigured to enable dynamic encoding that can be changed depending onthe usage of the electronic card 1700. For example, information storedon the coded magnetic component 1708 may be changed by the processingunit 1702 and/or an external encoder in response to a particular usecase or operation performed using the electronic card 1700. Theinformation stored may include an account balance, amount of value,authorization code, or other type of dynamic information.

As shown in FIG. 17, the electronic card 1700 may include a securitycomponent 1710, which may be used to authenticate the electronic card1700. In general, the security component 1710 includes an element orfeature that is or would be difficult to copy or counterfeit. In somecases, the security component 1710 may include a sticker or visualmarking having at least one feature that is difficult to copy orreplicate. For example, the security component 1710 may include asticker or marking having a holographic image, which is typicallydifficult to copy or replicate without sophisticated equipment. In somecases, the security component 1710 includes an embedded electronic code,electronic signature, or other electrically detectable element that isused to authenticate or identify the electronic card 1700. In general,the security component 1710 may be used to help determine that theelectronic card 1700 is authentic or not a counterfeit. In some cases,an external reader is configured to read or detect the securitycomponent 1710 and provide access to a restricted area, restrictedregion, or restricted system upon presentation of the electronic card1700.

The electronic card 1700 may include an antenna 1712. The antenna 1712may work in conjunction with the wireless circuitry 1706 to facilitatewireless communications with an external device or reader. In somecases, the antenna 1712 is passive and is used to communicate a serialnumber or other unique identifier to an external device or reader. Insome cases, the antenna 1712 may include or is configured as aradio-frequency identification (RFID) antenna, Bluetooth antenna,near-field communication (NFC) antenna, ultra-wideband antenna, or othersimilar component or device.

In some embodiments, the antenna 1712 is configured to receive and/ortransmit signals with multiple external devices in order to determine alocation of the electronic card 1700. For example, the antenna 1712 maybe used to transmit a beacon signal that is detected by one or moreexternal devices. Variations in the received signals from the variousdevices may be used to triangulate or calculate an estimated location ofthe electronic card 1700. In another example, the antenna 1712 of theelectronic card 1700 is a broadband antenna (e.g., an ultra-widebandantenna) that is configured to detect a range of signals emitted from avariety of devices. The electronic card 1700 may use the detectedsignals to estimate a current location.

The antenna 1712 may also include a NFC antenna that can be used toconduct transactions with a point of sale (POS) device or other externaldevice. In some implementations, the antenna 1712 may be configured tocommunicate with an antenna from another electronic card in order toauthenticate or initiate a transaction between two parties. In oneexample, the electronic card 1700 is configured to exchange cash or cardvalue when touched to or tapped against another similarly configuredelectronic card. The value exchange may be facilitated through a userinterface that is displayed on the electronic card 1700 (using, forexample, the display 1714) or that is displayed on another user deviceincluding, for example, a mobile phone, tablet, computer, or otherdevice.

The antenna 1712 may also be used to transmit alerts or notifications toa user device. In one example, the antenna 1712 is configured totransmit a signal that is received or relayed to a user device when theuser device moves out of a certain proximity of the electronic card1700. This functionality may be useful to prevent the electronic card1700 from being left in a business or other location unintentionally.The antenna 1712 may also be configured to receive instructions from auser device. For example, the antenna 1712 may be configured to receivea signal or relayed signal from a user device including instructions todisable the electronic card 1700. The instructions to disable theelectronic card 1700 may come from another system or device that may beoperated by the card issuer or other party.

In some implementations, the electronic card 1700 is shipped to the useror the customer in a container or package. The container or package maybe configured for shipment through the mail or other delivery service.The container or package may also be configured for display in a retailstore or setting. In some cases, the container or package is notconfigured for shipment without being placed into a separate shippingcontainer or package. For example, the exterior of the container orpackage may have a cosmetic appearance that would not be able towithstand normal shipping conditions intact or free of defects.

In some implementations, the container or package may include an antennaor electronic component that is able to be read by the user's mobilephone or other personal electronic device (e.g., tablet, notebookcomputer, desktop computer, personal media player). For example, thecontainer or package may include an envelope or pocket that theelectronic card 1700 may be placed at least partially within. Theenvelope or pocket may include a sleeve that fully encloses theelectronic card 1700 or may include a recess that partially encloses theelectronic card 1700 and leaves a top (or bottom) surface substantiallyexposed. The package may also include one or more flaps or panels thatare configured to fold over the envelope or pocket to conceal or coverthe electronic card 1700 contained therein.

The container may also include one or more antennas that extend alongone or more sides of the envelope or pocket. The one or more antennasmay include a near-field communication (NFC) antenna, a radio-frequencyidentification (RFID) antenna, or other type of antenna configured forwireless communication. In one example, the container includes twoelongated antennas that are located along opposite sides of the envelopeor pocket. The two elongated antennas may be offset in an outwarddirection from the edges of the electronic card 1700 when the electroniccard 1700 is positioned in the envelope or pocket of the container. Insome cases, one or more antennas encircle or at least partially surroundthe electronic card 1700 when the electronic card 1700 is held withinthe container. In some cases, the antennas overlap with one or moreportions of the electronic card 1700 when the electronic card 1700 ispositioned in the envelope or pocket of the container.

In some implementations, the user's personal electronic device is ableto identify the electronic card 1700 and obtain a serial number oranother type of unique identifier. The user's personal electronic devicemay obtain the identity of the electronic card 1700 by electricallycommunicating with the one or more antennas integrated with thepackaging. The user's personal electronic device may also be configuredto communicate to an external device and/or service in order to registerthe electronic card 1700 with a registry or user account. In some cases,the electronic card 1700 is activated in response to the registrationusing the user's personal electronic device.

In some embodiments, the electronic card 1700 includes one or morevisual output devices configured to provide output to a user. Forexample, the electronic card 1700 may include a display 1714 thatrenders visual information generated by the processing units 1702 orother form of graphical output. The display 1714 may include aliquid-crystal display (LCD), light-emitting diode, organiclight-emitting diode (OLED) display, an active layer organic lightemitting diode (AMOLED) display, organic electroluminescent (EL)display, electrophoretic ink display, or the like. If the display 1714is a liquid-crystal display or an electrophoretic ink display, thedisplay may also include a backlight component that can be controlled toprovide variable levels of display brightness. If the display 1714 is anorganic light-emitting diode or organic electroluminescent type display,the brightness of the display 1714 may be controlled by modifying theelectrical signals that are provided to display elements. The display1714 may be a foldable or flexible display that is configured to bebended or folded during normal operation.

In some implementations, the display 1714 is used to provide a dynamicor configurable marking for the electronic card 1700. For example, thedisplay 1714 may be used to display the card holder's name, accountnumber, card issuer logo, or other similar type of marking. In someimplementations, the display 1714 may dynamically change the markingdepending on the state or mode of the electronic card 1700. The display1714 may display an indicia or other marking indicating that value hasbeen loaded onto the electronic card 1700 and/or that the electroniccard 1700 is authorized to conduct a transaction or transfer of money.In some embodiments, the display 1714 may alter the orientation of themarking or graphical output depending on the orientation of theelectronic card 1700.

As shown in FIG. 17, the electronic card 1700 may also include a battery1716 that is configured to provide electrical power to the components ofthe electronic card 1700. The battery 1716 may include one or more powerstorage cells that are linked together to provide an internal supply ofelectrical power. The battery 1716 may be operatively coupled to powermanagement circuitry that is configured to provide appropriate voltageand power levels for individual components or groups of componentswithin the electronic card 1700. The battery 1716, via power managementcircuitry, may be configured to receive power from an external source,such as an external wireless charger. In one example, the battery 1716is operably coupled to a receive coil that is configured to receivewireless or inductively coupled power from a wireless charging devicehaving a transmit coil. The battery 1716 may store received power sothat the electronic card 1700 may operate without connection to anexternal power source for an extended period of time, which may rangefrom several hours to several days. The battery 1716 may be flexible toaccommodate bending or flexing of the electronic card 1700. For example,the battery 1716 may be mounted to a flexible structure or may bemounted to a flexible printed circuit. In some cases, the battery 1716is formed from flexible anodes and flexible cathode layers and thebattery cell is itself flexible. In some cases, individual battery cellsare not flexible, but are attached to a flexible substrate or carrierthat allows an array of battery cells to bend or fold around a foldableregion of the electronic card 1700.

In some embodiments, the electronic card 1700 includes one or more inputdevices 1718. The input device 1718 is a device that is configured toreceive input from a user or the environment. The input device 1718 mayinclude, for example, a touch sensor, a force sensor, or anothertouch-activated sensor. The touch-activated sensor may be used to definea touch-activated button, gesture input region, capacitive slide bar, orother touch-sensitive region on the electronic card 1700. The inputdevice 1718 may be configured to receive gesture input, force input, ora variety of other forms of touch input. In some embodiments, the inputdevice 1718 may provide a dedicated or primary function, including, forexample, a power button, home buttons, or other dedicated function oroperation.

As shown in FIG. 17, the electronic card 1700 may include one or moreoutput devices 1720. For example, the electronic card 1700 may includean output device 1720 that is configured to function as a speaker toproduce sounds or an audio output. In another example the output device1720 may be configured to operate as a tactile or haptic output deviceand produce a haptic output along a surface of the electronic card 1700.The output device 1720 may be formed from a mesh or matrix of fibers orwires that are configured to move or deform in response to a signal fromthe processing unit 1702. The movement of the mesh or matrix of fibersmay produce the tactile or haptic output along the external surface ofthe electronic card 1700. Similarly, the movement of the mesh or matrixof fibers may produce a sound or audio output.

In some embodiments, the electronic card 1700 includes one or moredevices that are configured to authenticate a user. For example, theelectronic card 1700 may include a bio-sensor that is configured toidentify or authenticate a user by detecting some uniquebio-characteristic including, for example, a fingerprint, a facialpattern, an eye detection, or other bio-data. The bio-sensor may, forexample, include a capacitive array that is configured to detect uniquefeatures of a user's fingerprint or touch. The bio-sensor may,alternatively, include an optical sensor that is configured to detectother unique characteristics of the user. The bio-sensor may be used toauthenticate a financial transaction, provide access to a restrictedarea, and/or unlock a device or system paired to the electronic card1700.

The following discussion applies to the electronic cards and electronicdevices described herein to the extent that these cards or devices maybe used to obtain personally identifiable information data. It is wellunderstood that the use of personally identifiable information shouldfollow privacy policies and practices that are generally recognized asmeeting or exceeding industry or governmental requirements formaintaining the privacy of users. In particular, personally identifiableinformation data should be managed and handled so as to minimize risksof unintentional or unauthorized access or use, and the nature ofauthorized use should be clearly indicated to users.

The foregoing description, for purposes of explanation, used specificnomenclature to provide a thorough understanding of the describedembodiments. However, it will be apparent to one skilled in the art thatthe specific details are not required in order to practice the describedembodiments. Thus, the foregoing descriptions of the specificembodiments described herein are presented for purposes of illustrationand description. They are not intended to be exhaustive or to limit theembodiments to the precise forms disclosed. It will be apparent to oneof ordinary skill in the art that many modifications and variations arepossible in view of the above teachings.

For example, features implementing functions may also be physicallylocated at various positions, including being distributed such thatportions of functions are implemented at different physical locations.Also, as used herein, including in the claims, “or” as used in a list ofitems prefaced by “at least one of” indicates a disjunctive list suchthat, for example, a list of “at least one of A, B, or C” means A or Bor C or AB or AC or BC or ABC (i.e., A and B and C). Further, the term“exemplary” does not mean that the described example is preferred orbetter than other examples.

What is claimed is:
 1. An electronic identification card comprising: ametal substrate having a first surface and a second surface and defininga recess extending into the first surface; a ferromagnetic film disposedat along the second surface of the metal substrate; an integratedcircuit disposed at least partially within the recess; and a firstcoating layer disposed over the metal substrate and comprising: a firstlayer that extends over the first surface of the metal substrate andcomprising a polymer and a pigment dispersed within the polymer; and asecond layer that extends over the first layer and comprises atransparent polymer.
 2. The electronic identification card of claim 1,wherein: the second layer has a hardness that is greater than the firstlayer; the second layer defines an exterior surface of the electronicidentification card; and the second layer has a surface roughness ofapproximately 0.5 um Ra.
 3. The electronic identification card of claim1, wherein: the first layer comprises a urethane primer that is adheredto the first surface of the metal substrate; the polymer of the firstlayer comprises a urethane that is adhered to the metal substrate by theurethane primer; and the second layer comprises a transparent acrylatethat defines a portion of an exterior surface of the electronicidentification card.
 4. The electronic identification card of claim 3,wherein: the electronic identification card further comprises a contactplate positioned over the integrated circuit; the portion of theexternal surface defined by the transparent acrylate is a first portion;and the contact plate defines an array of terminal electrodes thatdefine a second portion of the external surface of the electronicidentification card.
 5. The electronic identification card of claim 4,wherein each terminal electrode of the array of terminal electrodes isoffset from an edge of the contact plate.
 6. The electronicidentification card of claim 4, wherein the contact plate furthercomprises a conductive layer that surrounds the array of terminalelectrodes.
 7. The electronic identification card of claim 4, wherein:the contact plate comprises a plate substrate formed from a dielectricmaterial; and each terminal electrode comprises: a first layer formedfrom an electroless-plated metal and extending over the dielectricmaterial of the contact plate; and a second layer formed from anelectroplated metal and extending over the first layer.
 8. Theelectronic identification card of claim 1, wherein: the electronicidentification card defines a first set of chamfered edges that surroundthe first surface; and the electronic identification card defines asecond set of chamfered edges that surround the second surface.
 9. Theelectronic identification card of claim 8, wherein: the ferromagneticfilm is attached to a backing layer; a first chamfered edge is defined,at least in part, by a beveled edge formed within the ferromagnetic filmand the backing layer; and the first chamfered edge is congruent withthe beveled edge of the ferromagnetic film and the backing layer. 10.The electronic identification card of claim 1, wherein: the electronicidentification card further comprises a laser-formed relief featurecomprising: at least one recess wall defining a marking recess extendingthrough the first coating layer; and a recessed marking feature defininga bottom of the marking recess.
 11. The electronic identification cardof claim 1, wherein: the electronic identification card has arectangular shape with four corners, each corner having a contouredshape; and the contoured shape is a spline shape having a non-uniformradius of curvature.
 12. An electronic card comprising: a metalsubstrate defining a recess formed into a front surface; a ferromagneticfilm positioned along a rear surface of the metal substrate that isopposite to the front surface; an integrated circuit positioned in therecess of the metal substrate; a contact plate positioned over theintegrated circuit and comprising: a plate substrate; and an array ofterminal electrodes disposed over the plate substrate, each terminalelectrode of the array of terminal electrodes offset from an edge of theplate substrate.
 13. The electronic card of claim 12, wherein thecontact plate further comprises a set of ablated regions, each ablatedregion positioned between a respective terminal electrode of the arrayof terminal electrodes and a respective edge of the plate substrate. 14.The electronic card of claim 12, wherein: the contact plate furthercomprises a periphery portion that includes a conductive material thatsurrounds the array of terminal electrodes; and the periphery portion isseparated from the array of terminal electrodes by one or more ablatedregions.
 15. The electronic card of claim 12, wherein: the array ofterminal electrodes are disposed over a front surface of the platesubstrate; the contact plate further comprises a rear conductive layerdisposed over a rear surface of the plate substrate; and the array ofterminal electrodes are electrically coupled to the rear conductivelayer by one or more vias that extend through the plate substrate. 16.The electronic card of claim 12, wherein: the plate substrate is formedfrom a non-conductive material; and the array of terminal electrodescomprise: a first conductive layer including an electroless-plated metaldisposed over the non-conductive material of the plate substrate; and asecond conductive layer including an electroplated metal disposed overthe first conductive layer.
 17. A method of forming a contact plate foran electronic card, the method comprising: applying a photoresist layerto a front surface of a plate substrate; exposing the photoresist layerusing a light source to form a plating mask defining an array of platingareas; applying a catalytic solution to the array of plating areas toform a first conductive layer along a plating area of the array ofplating areas; applying a plating solution to the first conductivelayer; and while the plating solution is applied to the first conductivelayer, forming a second conductive layer over the first conductive layerusing an electroplating process that passes a current through the firstconductive layer to define a terminal electrode having an offset betweenthe terminal electrode and an edge of the plate substrate.
 18. Themethod of claim 17, wherein: the plate substrate is formed from anon-conductive material; the first conductive layer includes a bridgeportion that electrically couples the first conductive layer to the edgeof the plate substrate; and the method further comprises laser-ablatinga portion of the first and second conductive layers that is located atleast partially within the bridge portion to expose a portion of thenon-conductive material of the plate substrate.
 19. The method of claim18, wherein: a conductive periphery portion is positioned over the frontsurface of the plate substrate and at least partially surrounds theterminal electrode; and the bridge portion extends between the terminalelectrode and the conductive periphery portion.
 20. The method of claim17, further comprising: forming a rear conductive layer along a rearsurface of the plate substrate, the rear surface being opposite to thefront surface; and electrically coupling the first conductive layer tothe rear conductive layer using one or more vias that extend through theplate substrate.